Ultracom Installation and Servicing 24cx 30cx

Ultracom Installation and Servicing 24cx 30cx
Ultracom
Installation and Servicing
24cx
G.C. No. 47-019-06
30cx
G.C. No. 47-019-07
High Efficiency
Condensing Combination
Boilers
www.glow-worm.co.uk
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Guarantee Registration
Thank you for installing a new Glow-worm appliance in your home.
Glow-worm appliances are manufactured to the very highest standard so we are pleased to offer
our customers a Comprehensive Guarantee.
This product is guaranteed for 24 months from the date of installation or 30 months from the date
of manufacture, whichever is the shorter, for parts and labour.
The second year of the parts guarantee, from the beginning of the 13th month onwards after
installation or manufacture, is conditional upon the boiler having been serviced by a competent
person approved at the time by the Health and Safety Executive,
in accordance with the manufacturer’s recommendations. We strongly recommend regular
servicing of your gas appliance, but where the condition is not met, any chargeable spare parts or
components issued within the applicable guarantee period still benefit from a 12 month warranty
from the date of issue by the manufacturer.
We recommend you complete and return as soon as possible your guarantee registration card.
If your guarantee registration card is missing you can obtain a copy or record your registration by
telephoning the Glow-worm Customer Service number 01773 828100.
Customer Service:
01773 828100
Technical Helpline:
01773 828300
General and Sales enquiries:
Tel. 01773 824639
Fax: 01773 820569
To register your Glow-worm appliance call:
0800 0732142
Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided
with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s
instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark
Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future
reference.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of
Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme.
Visit www.centralheating.co.uk for more information.
2
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These instructions consist of, Installation, Servicing, Fault Finding, Replacement of Parts
and Spares. The instructions are an integral part of the appliance and must, to comply
with the current issue of the Gas Safety (Installation and Use) Regulations, be handed to
the user on completion of the installation.
CONTENTS
DESCRIPTION
INTRODUCTION
INSTALLATION
MAINTENANCE
SECTION
Warnings
Important Information
Statutory Requirements
Boiler Design
Safety Devices
Servicing, Maintenance and Spare Parts
PAGE
4
4
5
6
6
6
Boiler Specification
Boiler Dimensions &
Hydraulic Schematic
Boiler Location, Clearances
and Ventilation
Flue Options and Terminal Clearances
Water System
Installation Preparation
Boiler Fixing
Gas/Water Connections
Safety Discharge Valve and
Condensate Connections
Flue Length Preparation and Installation
Electrical Connection
Commissioning
1
7
2
8
3
4
5
6
7
8
9
10
12
14
16
16
9
10
11
12
18
20
36
38
Servicing
Fault Finding
Replacement of Parts
Spare Parts
Manual Handling
Declaration of Conformity
13
14
15
16
17
-
42
46
54
64
66
67
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3
WARNINGS
Gas Leak or Fault
Turn off the gas emergency control valve immediately. Eliminate all sources of ignition, i.e.smoking, blowlamps,
hot air guns etc. Do not operate electrical lights or switches either on or off. Open all doors and windows,
ventilate the area.
Metal Parts
This boiler contains metal parts (components) and care should be taken when handling and cleaning,
with particular regard to edges.
Sealed Components
Under no circumstances must the user interfere with or adjust sealed parts.
Important Information
Gas Category
50Hz supply.
This boiler is for use only on G20 natural gas, but may be
converted for use on G31 gas (Propane L.P.G.).
Connection of the whole electrical system of the boiler,
including any heating controls, to the electrical supply MUST
be through one common isolator and must be fused 3 Amp
maximum.
Gas Safety (Installation and Use) Regulations
In your own interests and that of safety, it is the Law that
ALL gas appliances are installed by a competent person
approved at the time by the Health and Safety Executive.
in accordance with the current issue of these regulations.
Control of Substances Hazardous to Health
Under Section 6 of The Health and Safety at Work Act
1974, we are required to provide information on substances
hazardous to health.
The adhesives and sealants used in this appliance are cured
and give no known hazard in this state.
Insulation Pads
These can cause irritation to skin, eyes and the respiratory
tract.
If you have a history of skin complaint you may be susceptible
to irritation. High dust levels are usual only if the material is
broken.
Normal handling should not cause discomfort, but follow
normal good hygiene and wash your hands before eating,
drinking or going to the lavatory.
If you do suffer irritation to the eyes or severe irritation to the
skin seek medical attention.
Manual Handling
With regards to the “Manual Handling Operations, 1992
Regulations”, the appliance exceeds the recommended
weight for a one man lift, refer to section 17 for more
information.
Electrical Supply
The boiler MUST be earthed.
All system components shall be of an approved type and all
wiring to current I.E.E. wiring regulations.
External wiring must be correctly earthed, polarised and in
accordance with the relevant standards.
In GB, this is BS 7671.
In IE, this is the current edition of ETCI rules.
The boiler MUST be connected to a permanent 230V ac,
4
Isolation should be by a double pole switched fused spur box,
with a minimum gap of 3mm for both poles. The fused spur
box should be readily accessible and preferably adjacent to
the appliance. It should be identified as to its use.
Alternatively connection can be made through an unswitched
shuttered socket and 3A fused 3-pin plug both to the current
issue of BS 1363, provided they are not used in a room
containing a bath or shower.
Wiring to the boiler must be PVC 85OC insulated cable, not
less than 0.75mm2 (24/0.20mm).
Testing and Certification
This boiler is tested and certificated for safety and
performance. It is, therefore, important that no alteration is
made to the boiler, without permission, in writing, by Glowworm.
Any alteration not approved by Glow-worm, could invalidate
the certification, boiler warranty and may also infringe the
current issue of the statutory requirements.
CE Mark
This boiler meets the requirements of Statutory Instrument,
No. 3083 The Boiler (Efficiency) Regulations, and therefore is
deemed to meet the requirements of Directive 92/42/EEC on
the efficiency requirements for new hot water boilers fired with
liquid or gaseous fuels.
Type test for purposes of Regulation 5 certified by: Notified
body 0087.
Product/production certified by: Notified body 0086.
The CE mark on this appliance shows compliance with:
1. Directive 90/396/EEC on the approximation of the laws
of the Member States relating to appliances burning gaseous
fuels.
2. Directive 73/23/EEC on the harmonisation of the Laws of
the Member States relating to electrical equipment designed
for use within certain voltage limits.
3. Directive 89/336/EEC on the approximation of the Laws of
the Member States relating to electromagnetic compatibility.
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Statutory Requirements
IMPORTANT
Gas Supply
Where no British Standards exists, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.
The gas installation must be in accordance with the relevant
standards.
The installation of this boiler must be carried out by a
competent person in accordance the rules in force in the
countries of destination.
In IE, this is the current edition of I.S.813 “Domestic Gas
Installations”.
Manufacturer’s instructions must not be taken as overriding
statutory requirements.
Statutory Requirements
In GB, the installation of the boiler must comply with the
requirements of the current issue of BS6798 and be carried
out by a competent person approved at the time by the
Health and Safety Executive. as described in the following
regulations:
The manufacturer’s instructions supplied.
The Gas Safety (Installation and Use) Regulations.
The appropriate Buildings Regulations either The Building
Regulations, The Building Regulations (Scotland),The
Building Regulations (Northern Ireland).
The Water Supply (water fittings) Regulations 1999 and water
byelaws 2000, Scotland.
The Health and Safety at Work Act, Control of Substances
Hazardous to Health (COSHH).
The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a competent
person approved at the time by the Health and Safety
Executive. and installed in accordance with the current edition
of I.S.813 “Domestic Gas Installations”, the current Building
Regulations and reference should be made to the current
ETCI rules for Electrical Installation.
In GB, this is BS6891.
The supply from the governed meter must be of adequate size
to provide a steady inlet working pressure of 20mbar (8in wg)
at the boiler.
On completion, test the gas installation for tightness using the
pressure drop method and suitable leak detection fluid, purge
in accordance with the above standard.
Domestic Hot Water
All domestic hot water circuits, connections, fittings must be
in accordance with the relevant standards and water supply
regulations.
GB: Guidance G17 to G24 and recommendation R17 to R24
of the Water Regulations Guide.
IE: The current edition of I.S.813 “Domestic Gas Installations”.
Heating System
In GB, it is necessary to comply with the Water Supply (Water
Fittings) Regulations 1999 (for Scotland, the Water Byelaws
2000, Scotland).
To comply with the Water regulations your attention is drawn
to: The Water Regulations guide published by the Water
Regulations Advisory Service (WRAS) gives full details of the
requirements.
In IE, the requirements given in the current edition of I.S.813
“Domestic Gas Installations” and the current Building
Regulations must be followed.
GB: the following Codes of Practice apply:
BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1,
BS5449, BS6891, BS6700, BS7074 Part 1 and 2, BS7593,
BS7671.
IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.
NOTE: For further information, see the current issue of the
Building Regulations, approved document L1 ( in the UK) and
the following current issues of:
1) Central heating system specification (CheSS)
and
2) Controls for domestic central heating system and hot water.
BRECSU.
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5
Boiler Design
Boiler Design
This boiler is designed for use as part of a sealed water
central heating system with fully pumped circulation. The
pump, expansion vessel and associated safety devices are
all fitted within the boiler. The optional integral programmer
is designed for both simple operation and maximum control.
Once the controls are set the boiler will operate automatically.
Condensate Drain
A plastic drain pipe must be fitted to allow discharge of
condensate to a drain.
Condensate should, if possible, be discharged into the internal
household draining system. If this is not practical, discharge
can be made externally into the household drainage system or
a purpose designed soak away, see section 9 for more details.
Pluming from flue terminal
Like all condensing boilers this appliance will produce a plume
of condensation from the flue terminal in cool weather. This is
due to the high efficiency and hence low flue gas temperature
of the boiler.
This is normal and not an indication of a fault.
Safety Devices
Electrical Supply Failure
Frost protection
The boiler will not work without an electrical supply.
The appliance has a built in frost protection device that
protects the boiler from freezing. With the gas and electric
supplies ON and irrespective of any room thermostat setting,
the frost protection device will operate the pump when the
temperature of the boiler water falls below 8OC.
Normal operation of the boiler should resume when the
electrical supply is restored.
Reset any external controls, to resume normal operation of
the central heating.
If the boiler does not resume normal operation press the reset
button. If the boiler does not resume normal operation after
this call your Installation/Servicing company or Glow-worm
service.
Overheating Safety
The boiler software is designed to recognise the potential for
an overheat lockout and will shutdown before this happens.
To restart the boiler, press the reset button on the controls
fascia.
If the boiler fails to resume normal operation and all external
controls are calling for heat, then call your Installation/
Servicing company or Glow-worm service.
Safety Discharge Valve
A safety discharge valve and discharge pipe are fitted to
the boiler. This valve must not be touched. Should there
be any discharge from the pipe, isolate the boiler electrical
supply and call your installer or Glow-worm’s own service
organisation using the telephone number on the inside front
cover of this booklet.
A timer is used so that the temperature can be checked
periodically. After 10 minutes the pump will be stopped if the
temperature is higher than 10OC or has already reached 35OC.
The burner will activate if the boiler temperature does not
reach 10OC after 30 minutes or at any time if the temperature
drops to 5OC.
The burner will switch off when the temperature reaches
35OC.
Condensate Drain Blockage
As a safety feature the boiler will stop working if the
condensate drain becomes blocked. During freezing
conditions this may be due to the forming of ice in the
condense drain external to the house. Release an ice
blockage by the use of warm cloths on the pipe, the boiler
should then restart.
Servicing, Maintenance and Spare Parts
6
Servicing and Maintenance
Spare Parts
To ensure the continued efficient and safe operation of the
boiler it is recommended that it is checked and serviced as
necessary at regular intervals. The frequency of servicing will
depend upon the particular installation conditions and usage.
If this appliance is installed in a rented property there is a duty
of care imposed on the owner of the property by the current
issue of the Gas Safety (Installation and Use) Regulations,
Section 35.
Servicing/maintenance should be carried out by a competent
person approved at the time by the Health and Safety
Executive. in accordance with the rules in force in the countries
of destination.
To obtain service, please call your installer or Glow-worm’s
own service organisation using the telephone number on the
inside front cover of this literature.
Remember, when replacing a part on this appliance, use
only spare parts that you can be assured conform to the
safety and performance specification that we require. Do not
use reconditioned or copy parts that have not been clearly
authorised by Glow-worm.
If a part is required contact Glow-worm’s own service
organisation.
Please quote the name of the appliance, this information will be
on the name badge on the front of the appliance.
If in doubt seek advice from the local gas company or Glowworm’s own service organisation using the telephone number
on the inside front cover of this booklet.
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1 Boiler Specification
13601
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7
2 Boiler Dimensions & Hydraulic Schematic
15421
13603
Diagram 2.2
2.1 Boiler Dimensions & Hydraulic Schematic
All dimensions are given in millimetres (except as noted).
The general arrangement of the boiler is shown in diagram
2.1. and the hydraulic and gas schematic, diagram 2.2.
The data label is positioned on the front of the inner casing
panel.
Diagram 2.1
8
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3 Boiler Location, Clearances and Ventilation
This boiler is not suitable for outdoor installation.
CLEARANCES
This boiler may be installed in any room, although particular
attention is drawn to the installation of a boiler in a room
containing a bath or shower where reference must be made to
the relevant requirements.
This boiler is suitable for installation in bathroom zones 2 and
3.
13712
3.1 Location
5
5mm clearance
to combustible
material
150
5
In GB this is the current I.E.E. WIRING REGULATIONS and
BUILDING REGULATIONS.
5
In IE reference should be made to the current edition of
I.S.813 “Domestic Gas Installations” and the current ETCI
rules.
3.2 Clearances
The boiler should be positioned so that at least the minimum
operational and servicing clearances are provided, see
diagram 3.1.
Additional clearances may be beneficial around the boiler for
installation and servicing.
For flue installations where external access is not practicable,
consideration should be given for the space required to insert
the flue internally, which may necessitate clearance larger
than those specified in diagram 3.1.
*5
600
3.3 Timber Frame Buildings
If the boiler is to be installed in a timber frame building it
should be fitted in accordance with the Institute of Gas
Engineers document IGE/UP/7/1998. If in doubt seek advice
from local gas undertaking or Glow-worm.
200
3.4 Combustible Material
The boiler and flue are suitable for installation onto and
through combustible materials provided that:1) Minimum 5mm clearance is maintained around the
circumference of the flue (air intake).
Diagram 3.1
2) The combustible surface and fixings are suitable for
supporting the load.
3) The minimum clearances from the boiler case are
maintained.
3.5 Room Ventilation
The boiler is room sealed so a permanent air vent is not
required.
3.6 Cupboard or Compartment Ventilation
Due to the high efficiency and hence low casing temperature
of this boiler, cupboard or compartment ventilation is not
necessary.
Leave existing air vents.
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9
4 Flue Options and Terminal Clearances
Top horizontal telescopic flue (Ø60/100)
Part No. A2043600 - Section 10, page 20
Ridge Tile Terminal
Part No. A2043800 Section 10, page 30
Top horizontal standard flue (Ø60/100)
Part No. A2043400 - Section 10, page 24
Plume Management Kit
basic set, white, concentric
flue (Ø60/100) - Part No.
A2044100 for use with Part
No. A2043400 and Part No.
A2043600 - Section 10, page 35
Twin Flue
Twin Flue Adapter, concentric flue (Ø80) Part No. A2011000 - Section 10, page 33
Multiple Boiler Chimney Flue
Vertical concentric stack flue
suitable for use with:Top horizontal telescopic flue,
Top standard horizontal flue,
Twin Flue, as specified by the
manufacturer.
Vertical Flue
Vertical Flue Adapter, concentric flue (Ø60/100) Part. No. A2024600 - Section 10, page 29
Vertical flue terminal kit, concentric flue (Ø60/100)
Part. No. 2000460480 - Section 10, page 29
Diagram 4.1
10
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4 Flue Options and Terminal Clearances
4.1 Flue Options
There are various flue options to choose from as illustrated in
diagram 4.1. The flue lengths and installation are described in
section 10.
4.2 Flue Terminal Position
In GB the minimum acceptable siting dimensions for the
terminal from obstructions, other terminals and ventilation
openings are shown in diagram 4.2.
In IE the minimum distances for flue terminal positioning must
be those detailed in I.S.813 “Domestic Gas Installations”.
The terminal must be exposed to the external air, allowing free
passage of air across it at all times.
Being a condensing boiler some pluming may occur from
the flue outlet. This should be taken into consideration when
selecting the position for the terminal.
Carports or similar extensions of a roof only, or a roof and
one wall, require special consideration with respect to any
openings, doors, vents or windows under the roof. Care is
required to protect the roof if made of plastic sheeting. If
the carport comprises of a roof and two or more walls, seek
advice from the local gas supply company before installing the
boiler.
HORIZONTAL FLUES
A DIRECTLY BELOW AN OPENING, AIR BRICK,
OPENING WINDOWS
300
B ABOVE AN OPENING, AIR BRICK,
OPENING WINDOWS
300
C HORIZONTALLY TO AN OPENING,
AIR BRICK, OPENING WINDOWS
300
D BELOW GUTTER, DRAIN/SOIL PIPE 25
E BELOW EAVES 25
25
F BELOW A BALCONY OR CAR PORT G FROM VERTICAL DRAIN PIPES AND SOIL PIPES 25
H FROM INTERNAL/EXTERNAL CORNERS
25
H *
I
J *
K
L
M
N
TO A BOUNDARY ALONGSIDE THE TERMINAL
300
ABOVE ADJACENT GROUND OR BALCONY LEVEL 300
FROM SURFACE OR A BOUNDARY
FACING THE TERMINAL 600
FACING TERMINALS 1200
FROM OPENING (DOOR/WINDOW) IN CAR PORT INTO DWELLING 1200
VERTICAL FROM A TERMINAL 1500
HORIZONTALLY FROM A TERMINAL 300
VERTICAL FLUES
FROM ANOTHER TERMINAL
ABOVE ROOF LEVEL
FROM ADJACENT OPENING WINDOW
FROM ADJACENT WALL TO FLUE
NOTE: If the flue terminal is positioned near a light source
insects may enter the flue system. Where safe and practical
to do so, advise the homeowner to check the flue outlet and
clear visible insects from the terminal end.
4.3 Terminal Guard
A terminal guard is required if persons could come into
contact with the terminal or the terminal could be subject to
damage.
If a terminal guard is required, it must be positioned to provide
minimum of 50mm clearance from any part of the terminal and
be central over the terminal.
The guard should be similar to that shown in diagram 4.3.
A suitable guard is manufactured by: Tower Flue Components
Morley Rd.
Tonbridge
Kent TN9 1RA.
Size: 280mm x 165mm. Part No. CGDK3
600
300
1000
300
15583
P
Q
R
S
H* and J* See diagram 4.2 . These dimensions comply with
the building regulations, but they may need to be increased to
avoid wall staining and nuisance from pluming depending on
site conditions.
Diagram 4.2
Diagram 4.3
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11
5 Water System
12800
5.1 General
This boiler is designed for use as part of a sealed water
central heating system with fully pumped circulation. The
pump, expansion vessel and associated safety devices are all
fitted within the boiler.
5.2 Safety Valve
The safety valve is an integral part of the boiler and it cannot
be adjusted. The pipe from the safety discharge valve must
not discharge above an entrance, window or any type of
public access area.
5.3 Expansion Vessel
The boiler has an integral expansion vessel with a capacity of
8 litres (1.76 gallons), with a charge pressure of 0.5bar.
NOTE: The expansion vessel volume depends on the total
water system volume and the initial system design pressure.
In GB, Guidance on vessel sizing is also given in the current
issue of BS5449 and BS7074 Part 1.
In IE, current edition of I.S.813 “Domestic Gas Installations”.
5.4 Flow Rate
If it is necessary to alter the flow rate, the system can be
fitted with a lockable balancing valve in the main flow or
return pipes shown as valve “A” in diagram 5.1. The flow rate
through the boiler must not be allowed to fall below that given
in section 1 - Specification Table.
5.5 Bypass
The boiler is fitted with an automatic bypass which can be
adjusted to suit your system requirements.
Ensure that under no circumstances does the flow rate drop
below the figure specified, refer to section 1 - Specification
Table.
Diagram 5.1
5.6 Filling the Sealed System
The boiler is supplied with a filling device, see diagram 8.1.
This filling device is designed to enable the filling and
pressurisation of the system in the event of loss of pressure.
NOTE: The water pressure at the boiler must be at least
1.2bar to enable filling the boiler to a minimum pressure. If
not pressurisation must be carried out by an alternative filling
loop.
5.8 Water Treatment
Existing system- It is ESSENTIAL that prior to installing the
new boiler the system is thoroughly flushed.
New system- For optimum performance after installation, the
boiler and its associated central heating system should also
be flushed.
Suitable external filling systems are shown diagrammatically,
see diagram 5.2. The system should be pressurized to 1bar,
indicated on the digital display with no heating demand.
Flushing should be carried out in accordance with BS7593:
2006 using a cleanser such as Sentinel X300 or X400, Fernox
Restorer or Salamander corrosion guard cleaner.
Draining taps must be provided at all low points of the system,
which will allow the entire system to be drained.
For long-term corrosion protection, after flushing, an inhibitor
suitable for stainless steel exchangers should be used, refer
to the current issue of BS 5449 and BS 7593 on the use of
inhibitors in central heating systems. Examples are Sentinel
X100 Fernox Protector or Salamander corrosion guard
inhibitor.to the current issue of BS 5449 and BS 7593 on the
use of inhibitors in central heating systems. Examples are
Sentinel X100 Fernox Protector or Salamander corrosion
guard inhibitor.
Ensure all cleanser is removed from the system.
5.7 Draining Points
Draining taps shall be to the current issue of BS2879.
Drain points for the appliance are provided at the positions
shown in diagram 8.1.
12
IMPORTANT: Ensure all cleanser is removed from the whole
system before adding an inhibitor.
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5 Water System
The minimum working pressure to obtain the maximum
domestic flow is:-
12253
5.9 Water Pressure
24cxi 1.0bar
30cxi 1.0bar
The maximum working pressure of the domestic hot water
circuit is 10 bar. If the cold water supply pressure exceeds
this, then a pressure-reducing valve must be fitted in the
supply to the boiler.
5.10 ‘Hard’ Water Areas
The temperatures within the heat exchanger are limited by
the boiler control system to minimise scale formation within
the hot water pipework. However, in areas where the water is
‘hard’ (i.e. more than 200mg/litre), it is recommended that the
hot water setting is reduced and that a scale reducer is fitted,
refer to the manufacturer’s instructions or consult the local
water company for additional advice.
5.11 Domestic Water Flow Rate
The domestic hot water flow has a restrictor, factory fitted,
which reduces the flow to a maximum of, 8.0 l/min for 24cx
and 12.0 l/min for 30cx.
Diagram 5.2
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13
6 Installation Preparation
Hanging Bracket
Gas and Water
Isolating Valves
0020036801
Electrical Cartridge
13646
Base Coverplate
Retaining Screws
stored in cartridge
Pipe Pack 0020029671
A - Central Heating x 2
B - Domestic Hot Water Outlet
C - Gas
D - Domestic Cold Water Inlet
E - Saftey Discharge
A
B
C
D
A
Loose Items Pack
A - Wire Retaining Clip
B - Union Nut and Sealing Washer
C - Tap and Securing Screw
D - Sealing Washers
E - Gas Sealing Washer
F - O Ring
G - Union Nut
A
B
E
E
C
F
G
D
Documentation Pack (not illustrated)
Wall Template, User Instructions, Installation and Servicing Instructions.
Diagram 6.1
14
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6 Installation Preparation
Please check the contents of packs as shown in diagram 6.1.
The packs are located in the top polystyrene packing.
13853
6.1 Appliance Pack
Remove the carton sleeve and top pack then lift the boiler and
its polystyrene base support out of the lower pack.
6.2 Site Requirements
The boiler mounting wall should be suitable for the weight of
the appliance and be true and flat.
NOTE: Due to the varied site conditions we do not supply
fixings and advise that the installer should supply those which
are suitable.
6.3 Wall Template
Take the wall template from the document pack located within
the top polystyrene packing and place in the desired position
on the wall, giving due consideration to the required boiler
clearances, see section 3, and the flue you are fitting.
Mark the position of the flue centre, if fitting a side flue, extend
the flue centre line into the corner then 158mm along the
adjacent wall.
For extended side flues, the flue hole centre should be
determined by extending the dashed inclined line on the
template to the side wall. This dashed line is drawn at 44mm/
metre (2.5°) rise from the boiler. Where this line reaches the
side wall, a horizontal line should be marked. The vertical
centre line of the flue should then be marked at 176mm from
the back wall.
Diagram 6.2
To allow for the flue passing through the wall at this angle
a 125mm hole should be drilled irrespective of internal or
external installation.
Remove the wall template whilst drilling the flue hole.
6.4 Flue Hole Cutting
External access flue installation can use a 105mm diameter
core drill.
Internal access only flue installation will need a 125mm
diameter core drill.
NOTE: The flue is designed with an internal fall of 44mm/
metre (2.5°), therefore the hole can be drilled horizontally.
If flue extension pipes are to be used then a core drill size of
125mm is required. This will allow the extension pieces to
slope at 44mm/metre (2.5°) towards the boiler.
Supplied By www.heating spares.co Tel. 0161 620 6677
15
7 Boiler Fixing
7.2 Boiler Hanging
7.1 Hanging Bracket Fixing
The Wall Hanging Bracket is supplied in the main boiler packaging at the rear of the boiler.
IMPORTANT: With regards to the Manual Handling
Operations, 1992 Regulations, the following lift operation
exceeds the recommended weight for a one man lift, refer to
section 17 Manual Handling.
Reposition the wall template over the flue hole and mark
the position of the fixing holes for the hanging bracket, see
diagram 7.1.
Lifting the boiler into position, lean the top of the boiler slightly
to the wall and position just above the hanging bracket. Lower
the boiler slowly and engage onto the hanging bracket, see
diagram 7.2.
Drill fixing holes and insert suitable wall plugs.
13713
13503
Diagram 7.2
Diagram 7.1
8 Gas / Water Connections
8.1 Systems Connection
Remove the protective caps from the boiler connections.
NOTE: The appliance may contain a small amount of water,
place a water container beneath the boiler connections
Assemble and secure the pre formed copper tails to their
respective isolation valves making sure of their correct
orientation, see diagram 8.1.
Fit the isolation valves/copper tails with seals to the appliance
as shown in diagram 8.1
Make sure that all connections are secured in the sequence
shown on diagram 8.1.
There are flats on the body of the valves for locating a
spanner to aid tightening.
Fit the Central Heating Isolation Valve handles and secure
with screws provided.
NOTE: Make sure the test and drain points are accessible,
refer diagram 8.1.
Plumb the system pipe work to the copper tails.
NOTE: Do not subject service cocks to heat.
Flush out the domestic hot water and the heating systems,
refer to section 5.8.
The whole of the gas installation, including the meter, should
be inspected, tested for tightness and purged in accordance
with the current issue of BS6891 and in IE the current edition
of I.S.813 “Domestic Gas Installations”.
Fit the ‘O’ ring seal from the loose items pack to the Double
Check Inlet Valve assembly then secure into isolation valve
with wire retaining clip, see diagram 8.1.
16
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8 Gas / Water Connections
13643
Diagram 8.1
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17
9 Safety Discharge Valve & Condensate Connections
13644
9.1 Safety Discharge Valve
Take the safety discharge pipe, supplied in the pipe pack and
the union nut and seal, supplied in the loose items pack and
fit as shown in diagram 9.1.
This must be extended, using not less than 15mm o.d. pipe,
to discharge, in a visible position, outside the building, facing
downwards, preferably over a drain.
To ease future servicing it is advisable to use a compression
type fitting to extend the safety discharge valve tube.
The pipe must have a continuous fall and be routed to a
position so that any discharge of water, possibly boiling,
or steam cannot create any danger to persons, damage to
property or external electrical components and wiring.
SAFETY
DISCHARGE
VALVE
9.2 Condensate Trap and Siphonic Drain
Connection
The condensate drain connection is behind the pump at the
rear of the boiler, see diagram 9.2. A flexible condensate
outlet pipe is fitted and should be used to couple the
condensate trap and siphonic drain to a 22mm to 25mm O.D.
non corrosive plastic pipe (overflow pipe).
IMPORTANT: Please remove the bung from the flexible pipe
before fitting to a drain outlet pipe.
UNION NUT
AND SEAL B
NOTE: the pipe should have a fall of a least 2.5O 44mm/metre
away from the boiler.
Condensate should, if possible be discharged into the
household internal drainage system. If this is not practicable,
discharge can be allowed into the external household drains
or a purpose designed soak away, refer to diagram 9.3.
The condensate is discharged periodically in ‘slugs’ by
siphonic action.
It is not necessary to provide air breaks or extra traps in the
discharge pipe as there is already a 75mm high trap inside
the boiler. Fitting an extra trap may cause the boiler siphon to
work incorrectly.
VIEW ON UNDERSIDE OF BOILER
Diagram 9.1
13645
It is recommended that any external condensate drain pipe is
protected and also preferably of 32mm diameter, to prevent
freezing in adverse weather conditions.
CONDENSATE
TRAP AND
SYPHONIC DRAIN
Refer to BS5546 or BS6798 for advice on disposal of boiler
condensate.
FLEXIBLE
CONDENSATE
OUTLET PIPE
FLEXIBLE
CONDENSATE
OUTLET PIPE
VIEW ON UNDERSIDE OF BOILER
18
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Diagram 9.2
13000
9 Safety Discharge Valve & Condensate Connections
Diagram 9.3
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19
10 Telescopic Flue - Length, Preparation and Installation
10.1 Flue Length
Horizontal Telescopic Flue
13558
The maximum permissible horizontal flue length is 10 metres
plus the flue terminal assembly, this can be achieved by use
of the accessories, see diagram 10.3.
However should an additional 87.5o or 2 x 45o elbows be
used then the length MUST be reduced by 1metre.
The diagram 10.1 shows the length achievable by using the
kit A2043600.
When extension pipes are used the flue system must be
designed to have a continuous fall to the boiler of at least 2.5o
44mm/metre to allow condensate to run back into the boiler
and out via the condensate drain.
The flue can be installed from inside the building, when
access to the outside wall face is not practicable.
The diagram 10.1 illustrates the lengths achievable without
the use of extensions or elbows.
Multiple Boiler Chimney Flue Length
The flue length must be calculated and installed according to
the relevant standards EN 13384-1 and 2 (C43 flue systems
only) with reference to the table below and the manufacturers
instructions supplied.
13559
The appliance maximum flue length must be included when
calculating the overall design of the flue system.
NOTE: The horizontal flue terminal must be removed, see
diagram 10.2.
MODEL
24cx
30cx
At Min Thermal
Load (40C°/30°C)
2.30
2.36
At Max Thermal
Load (80C°/60°C)
11.30
14.20
At Min Thermal
Load (40C°/30°C)
56.0
63.0
At Max Thermal
Load (80C°/60°C)
76.0
75.0
Exhaust mass rate (g/s)
Exhaust temperature (ºC)
Diagram 10.1
20
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10 Telescopic Flue - Length, Preparation and Installation
12841
Diagram 10.2
15418
Diagram 10.3
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21
10 Telescopic Flue - Length, Preparation and Installation
Refer to diagram 10.2 for kit contents.
13223
10.2 Horizontal Telescopic Flue - A2043600
10.3 REAR Flue
If a wall thickness is between 203mm min. to 413mm max.
then the flue can be used without extensions.
With the flue elbow temporarily fitted, measure the distance
from the outside wall to the butt joint, see diagram 10.4. If
the measurement ‘Y’ exceeds 525mm, then the appropriate
length of extension pipe is required.
If the dimension is less than 315mm DO NOT cut the flue, it
can project to a maximum of 600mm, refer to diagram 10.5. If
this is not desirable then a Standard flue MUST be used and
cut to length.
10.4 SIDE Flue
If the dimension is less than 315mm DO NOT cut the flue, it
can project to a maximum of 600mm, refer to diagram 10.5. If
this is not desirable then a Standard flue MUST be used and
cut to length.
Diagram 10.4
12979
With the flue elbow temporarily fitted, measure the distance
from the outside wall to the butt joint, see diagram 10.6. If
the measurement ‘Y’ exceeds 525mm, then the appropriate
length of extension pipe is required.
Diagram 10.5
13224
Diagram 10.6
22
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10 Telescopic Flue - Length, Preparation and Installation
12929
10.5 Flue Fitting
IMPORTANT:
The flue seals are sensitive to mineral oil based lubricants. Do
not grease the seals. If the seals do need to be lubricated
use only water.
During the installation of the flue system, ensure that debris
such as mortar, filings or swarf are cleared from the flue
system before completion.
Inspect the flue pipes before fitting and do not install damaged
or dented flue components.
When assembling the flue system, ensure that the inner
seals are not damaged, do not install a flue component with a
damaged seal.
When fitting flue elbows ensure that they are fitted at the
correct angle to avoid strain, this will ensure that the seal fits
correctly preventing leakage.
Diagram 10.7
With the air duct seams aligned and the flue set to the
required length ‘Y’, mark the securing hole position in the air
duct. Drill a 3mm diameter hole at this position, take care not
to pierce the inner flue duct. Secure with screw provided and
tape the joint, see diagram 10.7.
Fit the sealing collar onto the locating ring on the flue terminal,
see diagram 10.8.
12977
With the flue elbow removed, push the flue assembly into
the wall, externally or internally, until the end of the assembly
protrudes a short way from the inside face of the wall. This
will enable the internal trim ring (if required) to be positioned
and allow the flue assembly to be drawn back up to the flue
elbow.
Secure the flue elbow in position on top of the boiler with the
four screws supplied.
Draw the flue assembly from wall and engage the flue duct
into the elbow and butt fit between the air duct and flue elbow.
Fit the securing collar into position.
Ensuring correct alignment of the flue, mark through two of the
pre drilled holes in the securing collar.
Remove securing collar and drill two 3mm diameter holes one
in the elbow and one in the air duct, take care not to pierce the
inner flue duct. Fit the securing collar and secure with screws
provided, see diagram 10.9.
Diagram 10.8
Slide the internal trim ring back against the wall, securing in
place with a small amount of sealant if required.
13254
Insert the flue duct into the air duct terminal assembly,
remembering to engage the catch within the terminal.
Check that the outer rubber sealing collar makes an effective
seal against the wall face.
Diagram 10.9
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23
10 Standard Flue - Length, Preparation and Installation
10.6 Flue Length
Standard Horizontal Flue
13560
The maximum permissible horizontal flue length is 10 metres
plus the flue terminal assembly, this can be achieved by use
of the accessories, see diagram 10.12.
However should additional 87.5o or 2 x 45o elbows be used
then the length MUST be reduced by 1metre.
The diagram 10.10 shows the length achievable by using the
kit A2043400.
When extension pipes are used the flue system must be
designed to have a continuous fall to the boiler of at least 2.5o
44mm/metre to allow condensate to run back into the boiler
and out via the condensate drain.
The flue can be installed from inside the building, when
access to the outside wall face is not practicable.
Multiple Boiler Chimney Flue Length
The flue length must be calculated and installed according to
the relevant standards EN 13384-1 and 2 (C43 flue systems
only) with reference to the table below and the manufacturers
instructions supplied.
The appliance maximum flue length must be included when
calculating the overall design of the flue system.
13561
NOTE: The horizontal flue terminal must be removed, see
diagram 10.11.
MODEL
24cx
30cx
At Min Thermal
Load (40C°/30°C)
2.30
2.36
At Max Thermal
Load (80C°/60°C)
11.30
14.20
At Min Thermal
Load (40C°/30°C)
56.0
63.0
At Max Thermal
Load (80C°/60°C)
76.0
75.0
Exhaust mass rate (g/s)
Exhaust temperature (ºC)
Diagram 10.10
24
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10 Standard Flue - Length, Preparation and Installation
13222
Diagram 10.11
15418
Diagram 10.12
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25
10 Standard Flue - Length, Preparation and Installation
13223
10.7 Standard Horizontal Flue
Refer to diagram 10.11 for kit contents.
10.8 REAR Flue
With the flue elbow temporarily fitted, measure the distance
from the outside wall to the butt joint, see diagram 10.13. If
the measurement ‘Y’ exceeds 665mm, then the appropriate
length of extension pipe is required. The minimum dimension
is 187mm to suit a 75mm min wall thickness. The flue can
project to a maximum of 600mm, refer to diagram 10.14.
10.9 SIDE Flue
With the flue elbow temporarily fitted, measure the distance
from the outside wall to the butt joint, see diagram 10.15. If
the measurement ‘Y’ exceeds 665mm, then the appropriate
length of extension pipe is required. The minimum dimension
for Lhd is 254 and Rhd 226 to suit a minimum wall thickness
of 75mm. The flue can project to a maximum of 600mm, refer
diagram 10.14.
Diagram 10.13
12979
Diagram 10.14
13224
Left Hand illustrated
26
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Diagram 10.15
10 Standard Flue - Length, Preparation and Installation
10.10 Flue Fitting
12847
IMPORTANT:
The flue seals are sensitive to mineral oil based lubricants. Do
not grease the seals. If the seals do need to be lubricated
use only water.
During the installation of the flue system, ensure that debris
such as mortar, filings or swarf are cleared from the flue
system before completion.
Long lengths of flues must be secured to the walls or ceilings
they run against. Use at least one clip for every flue extension
that is used.
After cutting inner flue tubes ensure that you de-burr and
chamfer the male tube end to prevent damage.
Inspect the flue pipes before fitting and do not install damaged
or dented flue components.
When assembling the flue system, ensure that the inner
seals are not damaged, do not install a flue component with a
damaged seal.
When fitting flue elbows ensure that they are fitted at the
correct angle to avoid strain, this will ensure that the seal fits
correctly preventing leakage.
Remove the flue elbow.
Diagram 10.16
Separate the flue duct from the terminal by twisting to release
the terminal catch, then pull out of the retaining seal, refer to
diagram 10.16.
13254
The flue duct cutting length (L + 11mm.) is shown in diagram
10.16.
The air duct should be cut at the opposite end to the terminal
The plastic flue duct MUST be cut at the opposite end to the
terminal catch.
The plastic flue duct extensions MUST be cut at the opposite
end to seal.
Insert the flue duct into the air duct terminal assembly,
remembering to engage the catch within the terminal.
Fit the sealing collar behind the locating lugs on the flue
terminal, see diagram 10.17.
Push the flue assembly into the wall, externally or internally,
initially until the end of the assembly protrudes a short way
from the inside face of the wall. This will enable the internal
trim ring (if required) to be positioned and allow the flue
assembly to be drawn back into the flue elbow.
Secure the flue elbow in position on top of the boiler with four
torque headed screws supplied.
Diagram 10.17
Draw the flue assembly from wall and engage the flue duct
into the elbow and butt fit between the air duct and flue elbow.
Fit the securing collar into position.
Ensuring correct alignment of the flue, mark through two of the
pre drilled holes in the securing collar.
Remove securing collar and drill two 3mm diameter holes one
in the elbow and one in the air duct, take care not to pierce the
inner flue duct. Fit the securing collar and secure with screws
provided, see diagram 10.17.
Slide the internal trim ring back against the wall, securing in
place with a small amount of sealant if required.
NOTE: If the air and flue ducts have been correctly cut to the
instructions the sealing collar should fit flush with the outside
wall.
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27
10 Vertical Flue - Length, Preparation and Installation
10.11 Vertical flue
The vertical flue system is available as an option where the
boiler position does not permit the use of the top horizontal
flue system.
The system is made up from accessories. The accessories
include terminal assembly, bends 45º and 87.5º, flue
extensions, fixing bracket and appropriate weather collar, see
diagram 10.19.
Alternatively use 45º bends to avoid horizontal runs, see (b) in
diagram 10.18.
The terminal siting should be as shown in diagram 4.2.
Measure the distance of flue length required for the
installation.
The flue must be designed with a continuous fall towards the
boiler.
The maximum permitted straight flue length is 10 metres
plus the terminal. for each 87.5o or 2x45o bends fitted, the
maximum length must be reduced by 1 metre, see diagram
10.18.
14851
NOTE: 2x45º bends can replace 1x87.5º bend if necessary.
When using 87.5º bends any horizontal extension pipe should
be inclined by a minimum of 44mm/metre (2.5°) towards
the boiler to facilitate condense removal, see (a) in diagram
10.18.
Diagram 10.18
28
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10 Vertical - Flue Length, Preparation and Installation
14849
Flue Installation
IMPORTANT:
The flue seals are sensitive to mineral oil based lubricants. Do
not grease the seals. If the seals do need to be lubricated
use only water.
During the installation of the flue system, ensure that debris
such as mortar, filings or swarf are cleared from the flue
system before completion.
Long lengths of flues must be secured to the walls or ceilings
they run against. Use at least one clip for every flue extension
that is used.
After cutting inner flue tubes ensure that you de-burr and
chamfer the male tube end to prevent damage.
Inspect the flue pipes before fitting and do not install damaged
or dented flue components.
When assembling the flue system, ensure that the inner
seals are not damaged, do not install a flue component with a
damaged seal.
When fitting flue elbows ensure that they are fitted at the
correct angle to avoid strain, this will ensure that the seal fits
correctly preventing leakage.
Refer to diagram 10.21 and secure the flue adapter in position
on top of the boiler with the four screws supplied, making sure
the nib fits into the locating slot in the boiler casing to ensure
correct orientation.
Secure the first extension pipe to the flue adapter with the
securing collar supplied by positioning the collar centrally over
the joint, then tighten the two screws on the securing collar,
see diagram 10.22.
Fit more extension pipes as required using the collar and
screws supplied with each extension pipe. To fit position the
collar centrally over the joint, tighten the two screws on the
securing collar. Using the holes provided in the securing
collar drill and insert the two self tapping screws supplied, see
diagram 10.23.
The rubber ‘O’ rings of each section should be lubricated prior
to assembly.
Project the rise of the flue pipe to roof level and cut a 150mm
hole in the roof.
Flue Terminal Installation
(a) Pitched Roof
Fit the required pitched roof weather collar over the 150mm
hole in the roof. Make good the tiling or slating around the
collar incorporating the flashing of the weather collar. Position
the angle cap over the weather collar in the correct orientation
to attain the correct angle for your roof.
(b) Flat Roof
Fit the aluminium weather collar over the 150mm hole in the
roof ensuring a weather tight seal.
From above carefully place the flue terminal through the
weather collar.
Flue Terminal to Boiler Connection
Diagram 10.19
Should the clearances above the boiler to roof not allow for
extensions, it is permitted to cut the flue terminal ensuring the
relationship of flue and air duct lengths are retained.
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29
10 Vertical Flue - Length, Preparation and Installation
A ridge tile terminal is available - part no. A2043800, see
diagram 10.20.
14853
Ridge Tile Terminal
The installation of a ridge tile will be required.
A suitable ridge tile is manufactured by: Aspect East Anglia Limited
The Old Mill
East Harling
NORWICH
NR16 2QW
Website: www.aspectroofing.co.uk
Contact: Chris Haythorpe
General Manager - Tile Division
Tel: 01953 717777 Fax: 01953 717164
Diagram 10.20
30
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Completion of Installation
With the flue terminal positioned in the roof the length of the
final pipe can be determined. If a telescopic length cannot
be used, then a standard flue length can be cut to make the
correct length. Cut the flue to the desired length measuring
from the ‘O’ ring end and discard the plain end of the tube.
The cuts must be square and made free of burrs to allow
correct assembly.
13242
10 Vertical Flue - Length, Preparation and Installation
NOTE: The flue pipe is 10mm longer than the air pipe, see
diagram 10.24.
Carefully push the terminal assembly upwards to allow room
for fitting the final flue piece. Fit a fixing bracket to the terminal
assembly. Pull the terminal assembly down and join to the flue
system. Ensure that the terminal is making a weather tight
seal on the weather collar. Secure the fixing bracket fitted to
the terminal to the roofing struts or a purpose made batton.
13243
12982
Diagram 10.22
12983
Diagram 10.23
Diagram 10.21
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Diagram 10.24
31
15406
10 Twin Flue - Length, Preparation and Installation
Secure long flue lengths (horizontal &
vertical) to walls or ceiling at every joint or
on straight flue runs at every joint and
every metre flue run.
Diagram 10.25
32
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10 Twin Flue - Length, Preparation and Installation
14869
10.12 Twin flue
The twin flue system is available as an option when the top
horizontal or vertical flue system is not appropriate.
The system can provide an independent horizontal air inlet
and flue outlet, horizontal air inlet and vertical flue outlet or
vertical air inlet and flue outlet via a concentric terminal.
The system is made up from accessories, see diagram 10.26.
NOTE: The air and flue outlets do not have to be equal
lengths. 2x45° bends can replace 1x90° bend if necessary.
The maximum permitted combined (air inlet + flue outlet) flue
length is 40 metres plus terminal assemblies. For each 90° or
45° x 2 bends fitted, the maximum length must be reduced by
1 metre, see diagram 10.25.
NOTE: When using 90° bends any horizontal run should be
inclined by a minimum of 44mm/metre (2.5°) towards the
boiler to facilitate condense removal.
Alternatively use 45° bends to avoid horizontal runs in the flue
pipe.
Multiple Boiler Chimney Flue Length
The flue length must be calculated and installed according to
the relevant standards EN 13384-1 and 2 (C43 flue systems
only) with reference to the table below and the manufacturers
instructions supplied.
The appliance maximum flue length must be included when
calculating the overall design of the flue system.
NOTE: The horizontal flue terminal must be removed.
Terminal Position
The clearances for a flue outlet are given in the "Flue Location
and Ventilation" section.
In addition the horizontal air inlet must not be closer than 300
mm from a flue outlet on the same wall or 1200mm from an
opposing flue outlet.
MODEL
24cx
30cx
At Min Thermal
Load (40C°/30°C)
2.30
2.36
At Max Thermal
Load (80C°/60°C)
11.30
14.20
At Min Thermal
Load (40C°/30°C)
56.0
63.0
At Max Thermal
Load (80C°/60°C)
76.0
75.0
Exhaust mass rate (g/s)
Exhaust temperature (ºC)
Diagram 10.26
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33
10 Twin Flue - Length, Preparation and Installation
13240
Installation Details
The parts available for a twin flue system installation are
shown in diagram 10.26.
Boiler Connection
IMPORTANT: The flue seals are sensitive to mineral oil based
lubricants. Do not grease the seals. If the seals do need to
be lubricated use only water.
Place the twin flue adaptor onto the outlet of the boiler with
the air inlet to the left hand side, see diagram 10.27. Secure
the adaptor to the top panel with the screws provided. Care
should be taken when inserting the screw through the hole in
adaptor top.
To facilitate engagement, it is recommended that the rubber
‘O’ rings are lubricated with silicone grease or water prior to
assembly.
Air and Flue Pipe Installation
The air and flue pipes can now be built up from the boiler.
The flue must be designed with a continuous fall towards the
boiler. If using the horizontal flue pipe or 90° bends the pipe
must be inclined at 44mm/metre (2.5°) minimum, see diagram
10.25.
Alternatively if space allows, use 45° bends in place of 90º
bends.
To avoid rain ingress to the air Inlet terminal, it is good
practice to aim the inlet downwards by approx 2° as rain can
damage the boiler. The Flue outlet pipe must always run at
44mm/metre (2.5°) back to the boiler.
IMPORTANT:
Long lengths of flues must be secured to the wall or ceiling it
runs against. Use at least one fixing bracket on each flue joint
used or on straight flue runs every joint and for every metre
flue run.
Provision must be made in concealed boxing or ductwork that
the flue joints can be inspected during annual servicing.
The flue seals are sensitive to mineral oil based lubricants. Do
not grease the seals. If the seals do need to be lubricated
use only water.
Do not use the flue pipe to attach other pipes or equipment. If
visible, advise the householder not to hang or clip items to flue
pipes.
Do not stress the flue connections during the installation, this
can damage the flue seals.
Horizontal Terminal Installation
NOTE: The air inlet terminal and the flue outlet terminals
must never be installed on the opposite sides of a property.
Termination must only be on the same wall or adjacent walls.
When installed close together separated vertically, the air
inlet must be fitted below the flue outlet terminal (see diagram
10.25).
The air terminal must not terminate less than 20mm from an
adjacent wall or structure and the flue outlet terminal less than
100mm from any adjacent wall or structure.
With due consideration to terminal clearances mentioned in
Section 4.2 drill the one or two holes as required with a 90mm
core drill.
Push the horizontal terminal through the wall allowing approx.
100mm to protrude outside.
Push a grey rubber wall seal onto either side of the wall
ensuring that both wall seals are pushed up to the wall
surface, see examples (b) and (c) diagram 10.25.
34
Diagram 10.27
Vertical Terminal Installation
With due consideration to terminal clearances mentioned in
Section 4.2, project the rise of the flue pipe to roof level and
cut 150mm hole in the roof.
(a) Pitched Roof
Fit the required pitched roof weather collar over the 150mm
hole in the roof. Make good the tiling or slating around the
collar incorporating the flashing of the weather collar. Position
the angle cap over the weather collar in the correct orientation
to attain the correct angle for your roof. One way round gives
a pitch of 25°-38° and the other gives 37°- 50°.
(b) Flat Roof
Fit the aluminium weather collar over the 150mm hole in the
roof ensuring a weather tight seal.
Horizontal Pipes-Completion of Installation
Having built the pipe(s) from the boiler to the terminal(s), the
length of the final pipe piece can be determined. Cut pipes at
the opposite end to the ‘O’ ring seal making square and free
from burrs. Push the horizontal terminal through the wall to
engage the final pipe piece and pull back ensuring the grey
wall seals are fully pulled up to the outside and inside wall
faces.
Vertical Pipes-Completion of Installation
Refer to diagram 10.25.
For installation of (a), attach the twin pipe to concentric
flue adaptor, part number A2011600, to the base of vertical
terminal assembly. For installation of (b), attach the single
pipe to concentric adaptor, part number A2011500, to the base
of vertical terminal assembly.
With the vertical terminal assembly positioned in the roof,
the length of the final pipe can be determined. Cut the flue
to the desired length measuring from the ‘O’ ring seal end
and discard the plain end of the tube. The cut end should
be square and free from burrs. Carefully push the terminal
assembly upwards to allow room for fitting the final flue
piece(s). Fit a 100mm fixing bracket to the terminal assembly
Part No2000460486. Pull the terminal assembly down and
join to the flue system. Ensure that the terminal is making a
weather tight seal on the weather collar. Secure the fixing
bracket fitted to the terminal to the roofing struts or a purpose
made batton.
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12997
10 Plume Management Kit
10.13 Plume Management Kit
The Plume Management Kit: Part No. A2044100 (white) or
A2044000 (black) can be used to overcome many site issues.
The Plume Management Kit will fit to the Top Horizontal
Telescopic, Rear Horizontal Telescopic and Standard
Horizontal Flue. This enables the flue products to exhaust
further away from the boiler, thereby reducing the impact of
pluming.
NOTE: The flue air inlet can be sited closer to doors, opening
windows and air bricks, than stated in section 4.2, see
diagram 10.28.
The maximum length of the Plume Management Kit must NOT
exceed 6m with a horizontal concentric flue length of 2m max.
For each 90o bend or 2 x 45o bends the maximum length of the
Plume Management Kit must be reduced by 1m.
For more information contact Glow-worm, refer to page 2.
The Plume Management Kit is supplied with installation
instructions.
Refer to BS5546 or BS6798 for advice on disposal of boiler
condensate.
150mm.
MIN.
Diagram 10.28
10 Deflector Flue Terminal Kit
14465
10.14 Deflector Flue Terminal Kit
The terminal kit fits onto the telescopic and standard
horizontal flue, see diagram 4.1 for kit contents.
The kit is also supplied with installation instructions.
NOTE: The deflector flue terminal kit can be fitted after the
boiler and flue have been installed.
The deflector part of the deflector flue terminal can be rotated
45º to allow pluming away from openings, people, cars,
windows etc., see diagram 10.29.
Should the deflector terminal be positioned under a soffit or
horizontal surface, it is allowed to project the flue 600mm from
the wall, to allow the discharge of flue gases produced into
free air.
IMPORTANT: Do not fit the deflector flue terminal with the
deflector positioned downwards.
Diagram 10.29
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35
11 Electrical Connection
● This appliance must be wired in accordance with these
instructions. Any fault arising from incorrect wiring cannot be
put right under the terms of the Glow-worm guarantee.
● All system components must be of an approved type.
Electrical components have been tested to meet the equivalent
requirements of the BEAB.
● Do not interrupt the mains supply with a time switch or
programmer.
● Connection of the whole electrical system and any heating
system controls to the electrical supply must be through a
common isolator.
● Isolation should preferably be by a double pole switched
fused spur box having a minimum contact separation of 3mm
on each pole. The fused spur box should be readily accessible
and preferably adjacent to the boiler. It should be identified as
to its use.
● A fused three pin plug and shuttered socket outlet may be
used instead of a fused spur box provided that it is not used in a
room containing a fixed bath or shower.
● The boiler is suitable for installation in bathroom zones 2 and
3
13368
WARNING: This appliance must be earthed. 11.1 Electrical Wiring
Remove the electrical cartridge from the fittings pack.
Remove the securing screw to open the cartridge, see diagram
11.1.
NOTE: There are two screws supplied loose in the electrical
cartridge, these will be required to secure the cartridge into the
electrical interface housing.
Route the mains supply and system cables through the strain
relief and connect to the relevant plug, refer to the appropriate
sections 11.2 or 11.3 .
13369
Slacken the screws of the cable strain relief in the electrical
cartridge, see diagram 11.1.
Diagram 11.2
13302
Diagram 11.1
36
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Diagram 11.3
11 Electrical Connection
WARNING: UNDER NO CIRCUMSTANCES MUST
ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE
TERMINALS ON THE 24V CONNECTION PLUG.
13488
11.2 System Controls 24V
Connect the mains supply and system heating controls e.g.
room thermostat as diagram 11.2. External controls should be
fitted in accordance with the rules in force.
11.3 Mains Voltage System Controls
WARNING: UNDER NO CIRCUMSTANCES MUST
ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE
TERMINALS ON THE 24V CONNECTION PLUG.
Connect mains supply and system controls as diagram 11.3.
External controls should be fitted in accordance with the rules
in force.
11.4 Electrical Cartridge Securing
Fit electrical cartridge into the interface housing on completion
of the wiring, see diagram 11.4.
Secure with the two cartridge retaining screws provided in the
cartridge body.
11.5 Electrical Connections - Testing
Diagram 11.4
Carry out preliminary electrical system checks as below:
1. Test insulation resistance to earth of mains cables.
2. Test the earth continuity and short circuit of cables.
3. Test the polarity of the mains.
NOTE: If you require to test the appliance refer to section 14.
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37
12 Commissioning
IMPORTANT: At the time of commissioning, complete all
relevant sections of the Benchmark Checklist located in the
centre pages of this document.
12.1 Preliminaries - All Systems
12.3 Domestic Water Circuit
Do Not operate the boiler without water.
The commissioning should be carried out by a competent
person approved at the time by the Health and Safety
Executive and in accordance with the current issue of
BS6798.
Make sure that the system has been thoroughly flushed
out with cold water and that all cleanser if used has been
removed.
With the gas service isolation valve closed, with no demand
from any external controls and the power supply to the boiler
switched off.
Test for gas soundness and purge air from the gas supply.
Check that water flows from the hot water taps.
Check for water tightness of the complete domestic water
system.
The domestic hot water flow has a factory fitted restrictor,
which reduces the flow to a maximum of, 8.0 l/min for 24cx,
12.0 l/min for 30cx.
must be disconnected from the double check valve close the taps ‘E’ and ‘D’ then undo the knurled nut marked ‘A’ and pull the flexible hose from the double check valve.
Commissioning should only be carried out by a competent
person approved at the time by the Health and Safety
Executive.
12.2 Filling the Heating Circuit
CH WATER
TEMPERATURE
CONTROL KNOB
RESET
BUTTON
13705
Switch on the power supply to the boiler.
The boiler should be in “OFF” mode, this will be indicated
on the user interface display, refer to diagram 12.1. If not,
press the “Mode” button repeatedly until the “OFF” symbol is
displayed, then continue as follows:
1. Connect the flexible hose to the double check valve and secure by tightening the knurled nut marked ‘A’, refer diagram 12.2.
2. Open the Central Heating Flow and Return isolation valves marked ‘B’ using a screwdriver or a 4mm allen key - slot in line with the axis of the isolation valve (shown closed in diagram).
3. Ensure ALL cold water taps are shut off then open the Domestic Cold Water isolation valve marked ‘C’ using a screwdriver or a 3mm allen key - slot in line with the axis of the isolation valve (shown closed in diagram).
4. Open the tap ‘D’, then gradually open tap ‘E’ through 90o to fill the heating system to a pressure of 1.0bar then close the two filling taps.
5. Vent all air from the system - repeat step 4 as necessary until the system is full and all the air has been vented.
6. To comply with the water regulations the flexible hose LCD
DISPLAY
HOT WATER
ON / OFF
TEMPERATURE SWITCH
CONTROL KNOB
Diagram 12.1
13577
Diagram 12.2
38
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12 Commissioning
Commissioning should only be carried out by a competent
person approved at the time by the Health and Safety
Executive.
12.4 Initial Lighting
NOTE: The combustion for this appliance has been
checked, adjusted and preset at the factory for operation
on natural gas (G20) as defined on the appliance data
label.
No measurement of the combustion is necessary.
Having checked :
● the appliance has been installed in accordance with the instructions.
● the integrity of the flue system and flue seals.
● the integrity of the appliance combustion circuit and relevant seals.
● check that all external controls are calling for heat. If the integral programmer is fitted check that it is correctly programmed and if necessary overridden to provide heat.
● the gas service isolation valve ‘F’, diagram 12.2, is open.
LPG Conversion: See section 12.9.
The lighting procedure of the boiler is fully automated.
Ensure that both the central heating water temperature and
the hot water temperature control knobs are turned OFF (0).
Ensure the mains electrical supply and turn the mains reset
knob to (I) on the controls fascia.
Turn the central heating water temperature control knob to
MINIMUM.
The digital display will show water temperature in central
heating demand.
The fan should start and after a few seconds the ignition will
commence
If the burner fails to light the fan will stop. Initially this may be
due to air in the gas supply line. The boiler will automatically
have five attempts at ignition.
If necessary press the reset switch and the boiler will restart.
After the boiler has lit, allow to warm at MINIMUM
temperature setting to purge any air from the system.
The nominal supply pressure should be 20mbar (8in wg)
when the appliance is operating at the maximum heat input.
This can be achieved by turning on several hot water taps.
NOTE: There is a pressure drop over the gas service isolation
valve prior to the inlet pressure test point, this is normal and
the inlet pressure to the main gas valve can be up to 2mbar
less than the supply pressure to the boiler at the maximum
heat input. Additionally the safe nominal maximum heat input
of the appliance can be achieved at an inlet pressure down to
15mbar.
The gas valve is factory set for natural gas (G20) and should
need no adjustment. Should any doubt exist about the gas rate, check it using the
gas meter test dial and stop watch, at least 10 minutes after
the burner has lit, see table below, for approximate rates.
Make sure that all other gas burning appliances and pilot
lights are off.
It should be noted that the appliance will modulate the heat
input according to demand. This may affect the gas rates
measured if the appliance reaches its operating temperature
during the measurement.
Turn taps off and disconnect the pressure gauge.
Operational Gas Inlet Pressure
With ALL other gas appliances operating, check the
operational supply pressure at the gas service isolation valve
test point, see diagram 12.2.
The nominal supply pressure for Natural Gas (G20) is 20mbar.
The nominal supply pressure for LPG (G31) is 37mbar.
Turn the taps and appliances off, then disconnect the pressure
gauge.
Additionally the safe nominal maximum heat input of the
appliance can be achieved at an inlet pressure down to
15mbar.
NOTE: The BURNER PRESSURE cannot be measured and
is not used to measure the gas rate.
Gas Rate
Make sure that ALL other gas burning appliances and pilot
lights are off.
Check the gas rate using the gas meter test dial and stop
watch, at least 10 minutes after the burner has lit, see table
below for approximate rates.
13659
NOTE: If the appliance is operated above MINIMUM on initial
lighting, there is a possibility that the overheat lockout and
“F5” will be displayed on controls fascia, this is due to air not
having been completely purged. See diagram 12.1 for reset
button.
Once the system has been purged of air turn the Hot water
temperature control knob to the desired position and open a
hot water tap. The diverter valve motor will move to hot water
supply and the display will read system pressure. Check that
hot water is available and then close the hot water tap.
Turn the Central heating water temperature control knob to
the desired temperature.
The appliance will then continue to fire in central heating until
the user controls are satisfied or there is another demand
made for hot water.
12.5 Check the Gas Inlet Pressure and Gas
Rate
Check the supply pressure at the gas service isolation valve
test point, see diagram 12.2.
In communal or LPG installations where the gas rate cannot
be measured it is acceptable to measure the combustion rate
as described in the servicing section. Reset the boiler.
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12 Commissioning
12.6 Heating System
12.8 Instruct the User
Check that all remote controls are calling for heat. The boiler
will fire automatically. Fully open all radiator valves, flow
control valve ‘A’, if fitted, see diagram 5.1.
● Demonstrate, then instruct the User about the lighting
procedure and heating system controls operation.
● Advise that to ensure the continued efficient and safe
operation of the boiler it is recommended that it is checked
and serviced at regular intervals. The frequency of servicing
will depend upon the installation conditions and usage, but in
general, once a year should be enough.
● Draw attention, if applicable, to the current issue of the Gas
Safety (Installation and Use) Regulations, Section 35, which
imposes a duty of care on all persons who let out any property
containing a gas appliance in the UK.
● The user shall not interfere with or adjust sealed
components.
● It is the Law that any servicing is carried out by a
competent person approved at the time by the Health and
Safety Executive.
● Advise the user that, like all condensing boilers this
appliance will produce a plume of condensation from the flue
terminal in cool weather. This is due to the high efficiency and
hence low flue gas temperature of the boiler.
● Advise the user of the precautions necessary to prevent
damage to the system, boiler and the building, in the event of
the heating system being out of use during frost or freezing
conditions.
● Advise the user that the permanent mains electrical supply
SHOULD NOT be switched off, as the built in frost protection
and pump saver program will not operate.
● Advise the User if the mains electricity and gas are to be
turned off for any long periods during severe weather, it is
recommended that the whole system, including the boiler,
should be drained to avoid the risk of freezing.
NOTE: Sealed System: Contact your installation/servicing
company as draining, refilling and pressurising MUST be
carried out by a competent person approved at the time by
the Health and Safety Executive.
● Leave these instructions and the ‘Benchmark’ Installation,
Commissioning and Service Record with the user.
Balance the radiators as required and if fitted adjust valve to
give the required system differential. Turn off all radiators that
can be shut off by the user and check to see if less than the
maximum differential allowed of 20OC can be achieved across
flow and return.
NOTE: Should the system require that the appliance has
to be adjusted, the front casing will need to be removed as
described in the servicing section 13 and the control box
lowered into its service position.
The appliance pump has two speeds and can be adjusted
depending on the requirements of the system.
The appliance has an inbuilt automatic adjustable bypass
valve. The pressure can be adjusted between approx 1.5
and 3.5mH2O but is factory pre-set to approx 2.5mH2O.
The pressure changes by approx 0.1mH2O for each full turn
of the bypass screw, see diagram 12.3. Turning clockwise
increases the pressure and turning anti-clockwise decreases
the pressure.
Allow the system to reach maximum temperature then switch
off the boiler by isolating from the electrical supply.
Drain the entire system rapidly whilst hot, using the drain taps
at all the low points of the system. Fill and vent the system as
described previously in section 12.2.
Lock or remove the handle from control valve, if fitted.
Adjust the boiler temperature controls and any system
controls to their required settings.
12.7 Completion
Fit the coverplate, see diagram 12.4.
Ensure that the magnetic lighting instruction label is placed on
the surface of the boiler casing
GB: It is a requirement that the “Benchmark” Installation,
Commissioning and Service Record is completed and left with
the user.
IE: it is necessary to complete a “Declaration of Conformity” to
indicate compliance to I.S.813. An example of this is given in
the current edition of I.S.813.
13234
13539
Diagram 12.3
40
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Diagram 12.4
Natural Gas (G20) to LPG (G31) Conversion
13874
12.9 LPG CONVERSION - all models
G31 BURNER % CO2
Throttle
CO/CO2
TURNS
CHECK
MODEL (case on)
+ 0.0
24cx
9.2 to 10.2 10.0 - 0.9
0.004
30cx
0.3
10.0 to 11.0 10.5 +- 0.7
0.004
OFFSET
ADJUSTMENT
THROTTLE
SEALING
GROMMET
(3) Turn the throttle anti-clockwise by the number of turns
shown in the table.
(4) Ensure that the gas analyser is set to the correct fuel
setting - Propane.
(5) Attach combustion analyser to the combustion test point,
refer diagram 13.1.
IMPORTANT: Remember to replace the cap on
completion of the test.
(6) Turn on the mains electrical supply and turn on the gas
service isolation valve. Switch the boiler on.
(7) Generate a hot water demand by fully opening a hot
water tap. The boiler should fire automatically.
NOTE: If the appliance does not light and goes to lockout
(F1) turn the throttle anti-clockwise a further turn and
press the reset button, see diagram 12.1. The appliance
will (after a short delay) again attempt to fire. Repeat this
procedure (up to a total of 2 extra turns on the throttle
screw) until the appliance lights. PLEASE NOTE several
ignition attempts may be needed, to purge gas through
the appliance, before a successful ignition is achieved.
ELECTRICAL
PLUG
GAS PIPE
RETAINING
CLIP
Diagram 12.5
(1) Access the gas valve.
(2) Refer to diagram 12.5 and turn the gas valve throttle fully
clockwise.
13553
As an option, a chargeable boiler only commissioning service
can be provided by Glow-worm Service by calling telephone
No. 01773 828100.
NOTE: Steps 12.1 and 12.3 will need to be completed before
the appliance can be converted.
This conversion should only be carried out by a competent
person approved at the time by the Health and Safety
Executive.
During the conversion to Propane use of a suitable flue gas
analyser is necessary.
● The person carrying out a combustion measurement should
have been assessed as competent in the use of a flue gas
analyser and the interpretation of the results.
● The flue gas analyser used should be one meeting the requirements of BS7927 or BS-EN50379-3 and be calibrated in
accordance with the analyser manufacturers’ requirements.
● Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment, which covers the use of
electronic portable combustion gas analysers in accordance
with BS 7967, parts 1 to 4.
Tools required to make the conversion are a 2mm Allen key
and an electricians screwdriver.
Having checked :
● the appliance and system have been installed in
accordance with the instructions.
● the integrity of the flue system and flue seals....
● the integrity of the appliance combustion circuit and relevant
seals....
● that all internal/external controls are calling for heat.
● the gas service isolation valve ‘F’, diagram 12.2, is open
(10) To exit the check sequences press the “mode” and “+”
buttons simultaneously, this will reset the boiler to the
default display.
(11) Check the burner % CO2 , at minimum rate, to the value
shown in the “SETTING” column of the table.
(12) If adjustment is required, press the “reset” button on the
controls fascia, release and immediately press and hold
in the “+” button. After approximately 5 seconds “Hi” will
be displayed. Pressing the “+” or “-” buttons will cycle
between “Hi” and “Lo”. Pressing the mode button when
“Lo” is selected will force the boiler to minimum rate, the
display will flash between “Lo” and the “default display”
this will indicate the boiler has been forced to minimum.
(13) Adjustment of the %CO2 is very coarse so carefully
adjust the %CO2 to the value shown in the “SETTING”
column of the table with the offset adjustment, see
diagram 12.5 and %CO2 Table (Rotate clockwise to
increase).
(14) To exit the function press the “mode” and “+” buttons
simultaneously, this will reset the boiler to the default
display.
(8) Check and adjust the burner %CO2 at maximum rate.
(15) Repeat (8) and check CO2 at maximum rate - adjust if
necessary. Check that the CO/CO2 ratio is less than the
value in the table above.
(9)
Refer to diagram 12.1. Press the “reset” button on the
controls fascia, release and immediately press and hold
in the “+” button After approximately 5 seconds “Hi” will
be displayed. Pressing the mode button when “Hi” is
selected will force the boiler to maximum rate, the display
will flash between “Hi” and the “default display” this will
indicate the boiler has been forced to maximum.
Adjust, if necessary, the burner % CO2 to the value
shown in the “SETTING” column of the table, with the
throttle screw, see diagram 12.5 (rotate anti-clockwise to
increase).
Please remember after finishing this procedure to turn off
the hot water tap.
(16) Remove analyser probe from the test point and replace
the cap. Refit the control panel.
(17) IMPORTANT: Fit the LPG conversion label supplied
in the documentation pack to the inner front panel
alongside the data label. Refit the inner door and
outer door.
(18) Continue commissioning from 12.5.
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41
13 Servicing
1.
2.
3.
4.
5.
6.
IMPORTANT NOTES:
To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at
regular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once a
year should be enough.
It is the Law that any servicing is carried out by a competent person approved at the time by the Health and Safety
Executive.
Before commencing with a service or replacement of parts the boiler should be isolated from the electrical supply and the
gas supply should be turned off at the gas isolation valve.
When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and
performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised
by Glow-worm.
If any electrical connections have been disconnected and after their connection, checks to the earth continuity, polarity,
short circuit and resistance to earth must be repeated using a suitable multimeter, as described in section 14.
After servicing, complete the relevant Service Interval Record section of the Benchmark Checklist located in the centre
pages of this document.
13566
General Inspection
Prior to, during servicing and after any maintenance or
changed parts, the following must be checked.
● The integrity of the flue system and flue seals.
● The integrity of the appliance combustion circuit and
relevant seals.
● Electrical, gas and water connections.
● System pressure.
● the combustion performance, refer to the following
procedure.
● The operational gas inlet pressure and gas rates, refer to
the commissioning section paragraph 12.5.
Correct any fault before continuing.
COMPETENCY TO CARRY OUT THE CHECK
OF COMBUSTION PERFORMANCE
Diagram 13.1
13232
NOTE: BS 6798: 2009 Specification for installation and
maintenance of gas-fired boilers of rated input not exceeding
70kW net advises that:
● The person carrying out a combustion measurement must
be assessed as competent in the use of a flue gas analyser
and the interpretation of the results.
● The flue gas analyser used should be one meeting the
requirements of BS7927 or BS-EN50379-3 and be calibrated
in accordance with the analyser manufacturers’ requirements.
● Competence can be demonstrated by satisfactory
completion of the CPA1 ACS assessment, which covers
the use of electronic portable combustion gas analysers in
accordance with BS 7967, parts 1 to 4.
● Ensure that the gas analyser is set to the correct fuel
setting.
● Turn both temperature control knobs on the fascia to
maximum.
NOTE: Safe combustion can only be verified by measuring
CO/CO2 ratio. This must not exceed the value shown in the
table opposite.
FRONT
CASING PANEL
SECURING
SCREWS (2 OFF)
INNER CASING PANEL
SECURING
SCREWS (2 OFF)
COMBUSTION CHECK AND SETTING THE AIR/
GAS RATIO VALVE
● Remove the front casing panel, see diagram 13.2 and hinge
down the control box. Taking care not to touch any internal
components, proceed as follows:
● Connect the CO2 combustion analyser to the relevant test
point, see diagram 13.1.
42
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Diagram 13.2
13 Servicing
1. Maximum Rate Check and Adjustment
GAS RATE CHECK
NOTE: To verify the maximum gas rate CO2 setting the
appliance must be checked at the maximum rate first, refer to
diagram 12.1. Press the “reset” button on the controls fascia,
release and immediately press and hold in the “+” button.
After approximately 5 seconds “Hi” will be displayed. Pressing
the mode button when “Hi” is selected will force the boiler
to maximum rate, the display will flash between “Hi” and the
“default display” this will indicate the boiler has been forced to
maximum. Wait until the CO2 value is stable and check that
the value is within the range specified in table in the “check”
column.
If the combustion reading is not within the acceptable values
AND the integrity of the complete flue system and combustion
circuit seals have been verified and the inlet gas pressure
(and gas rate) have been verified, then, it will necessary to
adjust the combustion rate of the appliance.
NOTE: Adjustment is made by turning the gas valve
throttle an ⅛ of a turn, waiting 1 minute to allow the
appliance to stabilise before checking or making further
adjustments.
● Rotate the “throttle”(anti-clockwise to increase), to the
required CO2, refer to diagram 12.5 and the “SETTING”
column in the table.
● Exit the forced rate function, press the “mode” and “+”
buttons simultaneously, this will reset the boiler to the default
display. Now proceed to check the minimum rate adjustment.
Check the gas rates as described in the commissioning
section.
● Now check the minimum gas rate CO2 setting: Press
and release the “reset” button on the controls fascia, then
immediately press and hold in either of the “+” buttons. After
approximately 5 seconds “Hi” will be displayed. Pressing the
“+” or “-” buttons will toggle between “Hi” and “Lo”. Press the
mode button when “Lo” is selected, this will force the boiler
to minimum rate and the display will flash “Lo”, indicating the
boiler is operating at minimum.
● Wait until the CO2 value is stable and check that the value
is within the range specified in table in the “check” column.
If adjustment is necessary, proceed as follows:
NOTE: Adjustment of the CO2 at minimum rate is very
coarse and should not be adjusted more than an ⅛ of
a turn at a time. Wait 1 minute to allow the appliance to
stabilise before checking or making further adjustments.
● Gradually rotate the “offset adjustment” (anti-clockwise to
decrease) to the required CO2, refer to diagram 12.5 and the
“SETTING” column in the table.
● Exit the minimum rate function, press the “mode” and “+”
buttons simultaneously, this will reset the boiler to the default
display.
If it is not possible to achieve the required results for either
the combustion or gas rates, it will be necessary to complete
a full service of the appliance and then repeat the combustion
check procedure. If after servicing and adjustment of the
appliance the combustion values are still unacceptable and
after further remedial work has been carried out, the appliance
must be disconnected until the CO/CO2 ratio is acceptable.
Advice can be sought from the Glow-worm Technical Helpline.
13.1 Servicing
NOTE: If the Combustion CO2, CO/CO2 ratio & Gas rate
checks did not require adjustment then it will not be necessary
to complete a full service.
All routine servicing requirements can be achieved by the
removal of the front panel, see diagram 13.2. Position the
control box into the service position, see diagram 13.3.
Before commencing with a service or replacement of parts.
The boiler should be isolated from the electrical and gas
supplies.
13875
2. Minimum Rate Check and Adjustment
COMPLETION
G31 BURNER % CO2
MODEL
CHECK
(case on)
SETTING
(case off)
24cx
9.2 to 10.2
10.0
30cx
10.0 to 11.0
+ 0.0
- 0.9
+ 0.3
10.5
- 0.7
CO/CO2
ratio
0.004
0.004
G20 BURNER % CO2
MODEL
CHECK
(case on)
SETTING
(case off)
24cx
8.5 to 9.6
9.1
30cx
8.5 to 9.6
9.1
● Re-check the maximum and minimum CO2 values to
ensure that they are within the “setting” limits in the table
then check the CO/CO2 combustion ratio does not exceed
the value in the CO/CO2 column of the table. If the CO/CO2
setting exceeds the value in the table, a complete servicing of
the appliance will be necessary, refer to section 13.1.
If the CO2 and the CO/CO2 ratio falls within the tolerances
quoted, exit the function press the “mode” and “+” buttons
simultaneously, this will reset the boiler to the default display.
Remove the analyser probe and replace the cap on the
sampling point, replace the controls fascia, inner and front
casing panels.
IMPORTANT: Remember to replace the sample point cap on
completion of the test.
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0.004
0.004
13517
3. Re-Check CO2 and check the CO/CO2 combustion ratio.
+ 0.2
- 0.5
+ 0.2
- 0.5
CO/CO2
ratio
Diagram 13.3
43
13 Servicing
13.2 Spark Electrode
13.3 Burner
Disconnect the spark electrode plug and earth lead. Remove
the two securing screws and withdraw the spark electrode
carefully from the combustion chamber, see diagram 13.4.
Inspect the tips for damage.
Clean away any debris and check the spark gap is 3.5 to 4.5
mm.
Check the electrode gasket for signs of damage and replace if
necessary.
NOTE:
● The following procedure will require that you replace the
burner door seal and nyloc nuts.
● Removal of the burner is not necessary during a normal
service, but if it is removed it will require a new gasket, see
diagram 13.6.
● When replacing ensure that the sealing grommet, situated
below the gas valve is correctly re-seated.
13515
Disconnect the gas valve electrical plug at the gas valve, see
diagram 13.5.
Disconnect the electrical plug from the fan.
Disconnect the spark electrode plug and earth lead, refer to
diagram 13.6.
Remove the gas pipe retaining clip.
Remove the five combustion chamber/burner door securing
nuts, see diagram 13.7, these should be discarded and
replaced with the new nylocs nuts supplied in the burner door
seal kit.
Gently remove the fan, gas valve and burner assembly from
the combustion chamber.
Clean the burner with a soft brush taking great care not to
damage the front insulation. DO NOT use wire or sharp
instruments to clean the holes of the burner.
Inspect the burner for any signs of damage.
Remove and discard the burner door seal and replace with
new, see diagram 13.7.
13266
Diagram 13.4
13518
Diagram 13.5
44
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Diagram 13.6
13 Servicing
13555
Diagram 13.7
13272
13.4. Combustion Chamber and Heat
Exchanger
Remove loose debris from inside the combustion chamber
using a soft brush and vacuum cleaner.
Carefully flush by spraying water into the heat exchanger, any
remaining debris should pass through the condensate trap
(Ensure the water is kept away from electrical components).
13.5 Inner Casing Panel Seal check
Check the condition of the seal, if worn or damaged remove
the seal and thoroughly clean the casing surface before fitting
the new seal, see diagram 13.8.
Refit the inner casing panel.
NOTE: Ensure the seal is fitted correctly giving an airtight
joint.
13.6 Service Completion
Re-check the combustion as described at the beginning of
this section.
On completion of the service the “Benchmark” Service Record
should be completed.
Diagram 13.8
NOTE: If the burner is not to be serviced, do not perform the
following instructions 13.5, 13.6, 13.7 and 13.8 but continue to
section 13.9 to complete the servicing.
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45
14 Fault Finding
13535
14.1 Preliminary fault finding
The following checks should be performed before proceeding
onto specific diagnostics:
• Check the external electrical supply to the boiler is on and
a supply of 230V is present at the ‘L’ and ‘N’ terminals on
the installer interface, refer to section 11.5 for access and
diagram 14.4.
• Check the electrical installation and appliance, carry
out tests for earth continuity, polarity, short circuit and
resistance to earth, using a suitable multimeter.
An aid to test
Remove the front casing panel, see diagram 13.2 and the
control panel securing screw, see diagram 14.1 then lower
into service the position.
Remove the rear panel by prising the retaining clips, see
diagram 14.1.
Carry out the tests at connector plug X17, see diagram 14.2.
Check chassis earth at a bare metal point on the boiler.
Diagram 14.1
13845
• Check that there is a gas supply to the boiler and the gas
service isolation valve is turned on, see diagram 12.2.
• Check pressure at the gas service isolation valve, refer to
section 12.5.
• Check that the heating system pressure indicates at least
1mb, if not, fill and vent the system as described in section
12.2.
• Check that all external controls are on.
• Check the functional flow diagram, 14.5.
14.2 Fault Codes
Fault codes take priority over all other display functions in the
event of a fault occurring, refer to diagram 14.6.
If multiple faults occur the codes will be displayed for approx.
2 seconds, alternatively.
14.3 Fault Memory
On the left hand side of the ebox there are three buttons, see
diagram 12.1, for use only by the installer, these can only be
accessed when the case is removed.
Diagram 14.2
13709
The Fault memory stores details of the ten most recent faults.
Refer to diagram 12.1.
To access this menu:
a) Press and hold ‘MODE’ and ‘-’ for 5 seconds.
b) Press ‘+’ button to scroll back through the fault memory
(Position 1 is most recent), see fault memory display.
To exit this menu, press the ‘MODE’ button.
FAULT MEMORY POSITION
14.4 Diagnostic Menu
The Diagnostic Menu provides the ability to view and
change certain parameters. See diagram 14.8 for available
parameters.
14.5 Status Codes
The status codes provide information about the current
operating condition of the boiler and can be accessed through
the diagnostic display, refer to diagram 14.9.
FAULT CODE
DISPLAY FLASHES ALTERNATELY BETWEEN THE
CURRENT FAULT MEMORY POSITION AND THE
FAULT CODE.
Diagram 14.3
46
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14 Fault Finding
13706
y
b
w
bk
r bk
r
gy
w
g/y
b
w
or
p
bk g
pk
w
gy
g/y
w
g/y
r
w
bk
b
r
bk
REFER TO
SECTION 11
ELECTRICAL
CONNECTION
b
b
r
BROWN
BLUE
GREEN/YELLOW
GREY
GREEN
BLACK
YELLOW
RED
WHITE
ORANGE
PURPLE
PINK
g/y
g/y
bk
b
br
bk
g
w
b
KEY
br
b
g/y
gy
g
bk
y
r
w
or
p
pk
br
b2
w
4
6
br
or
r
r
b
r
1
3
5
Diagram 14.4
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47
14 Fault Finding
13015
DHW
13012
CENTRAL HEATING
Diagram 14.5
48
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14 Fault Finding
13860
Fault Codes
If -9OC is displayed, check that the DHW thermistor wires are unconnected and are not faulty or
trapped.
Diagram 14.6
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49
14 Fault Finding
13508
Fault Codes (continued)
Diagram 14.6 continued.
50
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14 Fault Finding
Diagnostic Menu
The Diagnostic Menu provides the ability to view and
change certain parameters. See Diagram 14.8 for available parameters.
To enter the diagnostic menu:
a) Press and hold the ‘MODE’ and ‘+’ button for 5
seconds. The display will change to ‘0’.
b) Use the ‘+’ or ‘-’ buttons to scroll to 96 (This is the
installer level access password).
c) Press and hold ‘MODE’ for 5 seconds to confirm, see
diagram 14.6.
13707
INSTALLER LEVEL
DIAGNOSTIC NUMBER
DISPLAY FLASHES ALTERNATELY BETWEEN
THE INSTALLER LEVEL AND THE
DIAGNOSTIC NUMBER.
Diagram 14.7
Use the ‘+’ or ‘-’ buttons to view the appropriate
diagnostic number, see diagram 14.7.
a) Press ‘MODE’ to see appropriate value.
b) Press ‘MODE’ again to return to main diagnostic
menu.
c) The values can be changed by pressing ‘+’ or ’-’
when the value is displayed.
d) Press and hold ‘MODE’ 5 seconds to confirm.
(NOTE: Only certain parameters can be adjusted)
To exit the diagnostic menu press the ‘MODE’ and ‘+’
buttons.
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51
14 Fault Finding
13454
Diagnostic Menu - Level 1 Installer Access
(see State Lists table)
Indicates read and write function - all other diagnostics are read only
Diagram 14.8
52
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14 Fault Finding
13011
State list - Accessed through Diagnostic Codes - Level 1, Installer Access d.99
STATE LISTS
Central heating mode
S.00
S.01
S.02
S.03
S.04
S.05
S.06
S.07
S.08
no heating required
fan pre-run
pump pre-run
ignition
burner on
pump / fan overrun
fan overrun
pump overrun
Anti cycling period
Description
NORMAL OPERATING
STATE FOR CH MODE
Domestic hot water mode
S.10
S.11
S.13
S.14
S.15
S.16
S.17
domestic hot water demand
fan pre-run
ignition
burner on
pump / fan overrun
fan overrun
pump overrun
NORMAL OPERATING
STATE FOR DHW MODE
Preheat mode
S.20
S.21
S.22
S.23
S.24
S.25
S.26
S.27
S.28
domestic hot water cycling mode active
fan pre-run
Pump pre run
ignition
burner on
pump / fan overrun
fan overrun
pump overrun
Anticycling period
NORMAL OPERATING
STATE FOR PRE-HEAT MODE
Special cases of status messages
S.30
No Heating demand from external controls 230V
Check wiring in external controller.
Check wiring at Installer Interface.
S.31
S.32
Check CH setpoint / Check external controls
Check fan connection.
S.34
summer mode
Antifreeze active – fan speed variation too high
– waiting during blocking function
frost protection active (Priority 4)
S.36
No Heating demand from external controls 24V
S.42
S.53
Accesory Module is blocking burner operation
waiting time: temperature difference flow
- return sensor too high (Check thermistor fit)
S.54
waiting time: no water in system, temperature
(gradient error) rise flow / return sensor too high
S.76
S.96
Waiting period – pressure sensor
Return-Sensor check is running, demand
(DHW or heating) is blocked
Water pressure sensor check is running,
demand (DHW or heating) is blocked
Flow / Return - sensor check is running, demand
(DHW or heating) is blocked
S.97
S.98
Temperature below 8O C - check thermistor
connection if this is not true.
Check wiring in external controller.
Check wiring at Installer Interface.
Check accessory module.
Check flow & return thermistor connections to pipes.
Check harness connection to thermistor.
Check harness wires are not trapped between any
internal components.
Check flow & return thermistor connections to pipes.
Check harness connection to thermistor.
Check harness wires are not trapped between any
internal components.
Check system pressure - default display.
Check return thermistor connection to pipe.
Check harness connection to thermistor.
Check connection to pressure sensor.
Check pump has not seized.
Check flow & return thermistor connections to pipes.
Check harness connection to thermistor.
Check harness wires are not trapped between any
internal components.
Diagram 14.9
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53
15 Replacement of Parts
13274
15.1 General
IMPORTANT: The replacement of parts described in sections
15.5 to 15.9 and section 15.12 will require the removal of the
burner module assembly and the replacement of the burner
door seal and self locking nuts.
Replacement parts that have associated components that
need replacing on removal, i.e. ‘O’ ring, seals, gasket, etc.,
will be supplied and should be fitted.
Replacement of parts must be carried out by a competent
person approved at the time by the Health and Safety
Executive.
Before replacing any parts the boiler should be isolated from
the mains electric supply and the gas should be turned off
at the gas service isolation valve on the boiler, see diagram
12.2.
Unless stated otherwise parts are replaced in the reverse
order to removal.
After replacing any parts always test for gas soundness and if
necessary carry out functional test of the controls.
For replacement of parts the front casing and the inner casing
panel of the boiler will need to be removed. To remove undo
the two screws on the underside of the front casing and lift off.
Undo the two screws on the front of the inner front panel and
lift off.
If the appliance site situation has sufficient side clearances
the side panels can be hinged sideways and removed to aid
replacement of parts.
To remove a side panel undo the three screws securing each
side panel to the boiler, two at the front and one at the top.
Draining of Boiler Heating Circuit
Drain down the Heating Circuit of the boiler only, by closing
the heating flow and return isolating valves, see diagram 8.1.
Attach a length of hose to the drain point and open the drain
valve, see diagram 8.1.
After replacing part, close the drain valve and remove the
hose. Open the heating flow and return isolating valves and
refill, vent and pressurise the heating circuit, see section 12.6.
Diagram 15.1
15.3 Igniter Unit
For access, refer to section 15.1.
Remove ignition lead and electrical connections then remove
igniter unit by removing two securing screws, see diagram
15.1.
15.4 Ignition Lead
For access, refer to section 15.1.
Pull the spark plug style connector off the spark electrode,
refer to diagram 13.6. and the spade connector connected to
the igniter unit, see diagram 15.1.
Check for leaks.
Draining of Boiler Hot Water Circuit
Drain the Domestic Hot Water circuit by closing the cold-water
isolation valve on the wall mounting jig.
Open one or more hot water taps to drain the hot water circuit.
After replacing part open the cold-water isolation valve and
slowly open a hot water tap to remove air. Close the hot water
tap and check for any leaks.
15.2 Spark Electrode
For access, refer to section 15.1.
Refer to section 13.2 for removal.
54
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15 Replacement of Parts
13276
15.5 Gas Valve
For access, refer to section 15.1.
Refer to section 13.3 for removal of the fan, gas valve and
burner assembly.
Before removing the gas valve note its orientation in
relationship to the fan.
Remove the three securing screws, which also secures the
plastic swirl plate to the venturi on the fan, see diagram 15.2.
Withdraw the gas valve.
After assembly test for gas tightness and purge in accordance
with the current issue of BS6891or in IE, the current edition of
I.S.813 “Domestic Gas Installations”.
Check the combustion CO2 and adjust if necessary, see
section 13.
15.6 Fan
For access, refer to section 15.1.
VENTURI
PLATE
SECURING
SCREW (3)
Diagram 15.2
Refer to section 12.3 for removal of the fan, gas valve and
burner assembly.
13238
Remove the gas valve as described in section 15.5.
Remove the two securing screws, nuts and washers to
separate the fan from the gas manifold extension tube and
gas manifold, see diagram 15.3.
After assembly test for gas soundness and purge in
accordance with the current issue of BS6891or in IE, the
current edition of I.S.813 “Domestic Gas Installations”.
15.7 Burner
For access, refer to section 15.1.
Refer to section 13.3 for removal of the fan, gas valve and
burner assembly.
Remove the four screws that secure the burner, see diagram
13.7.
NOTE: The burner will require a new gasket.
15.8 Front Insulation
Diagram 15.3
For access, refer to section 15.1.
WASHER
Remove burner as described in section 15.7.
REAR
INSULATION
Remove spark electrode, see section 15.2.
13277
Refer to section 13.3 for removal of the burner module.
NOTE: The burner will require a new gasket when refitted.
15.9 Rear Insulation
For access, refer to section 15.1.
Refer to section 13.3 for removal of the burner module.
Remove securing screw and washer in the centre of the
insulation and withdraw insulation, see diagram 15.4.
HEAT
EXCHANGER
SECURING SCREW
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Diagram 15.4
55
15 Replacement of Parts
FIBRE WASHER
For access, refer to section 15.1.
GLASS
13278
15.10 Viewing Window
Refer to diagram 15.5.
Remove circlip.
Remove steel washer.
Remove glass.
Remove fibre washer.
15.11 Expansion Vessel
For access, refer to section 15.1.
Drain the boiler heating circuit as described in the appropriate
section of 15.1.
CIRCLIP
Undo the coupling at the base of the vessel, see diagram
15.6.
While holding the vessel remove the securing bolt on the top
panel of the boiler. Remove upper support bracket.
STEEL WASHER
Fit a new gasket between the expansion vessel and coupling.
13279
Refill, vent and pressurise the boiler.
Diagram 15.5
Diagram 15.6
56
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15 Replacement of Parts
Refer to Manual Handling section on page 65.
13570
15.12 Heat Exchanger
For access, refer to section 15.1.
Refer to section 13.3 for removal of the fan, gas valve and
burner assembly.
Drain the boiler heating circuit as described in the appropriate
section of 15.1.
Drain the boiler hot water circuit as described in the
appropriate section of 15.1.
Remove the clip securing the condense hose adapter to heat
exchanger, refer to diagram 15.7.
Pull the condense pipe adapter off the heat exchanger
connection.
Disconnect the central heating flow and return pipes from the
heat exchanger.
Move the pipes away from the heat exchanger.
Slacken the three heat exchanger securing screws and
clamps (two at the top and one at the bottom) to remove the
heat exchanger, see diagram 15.8.
Carefully ease heat exchanger out.
13522
CAUTION: There will be water in the heat exchanger.
Diagram 15.7
15.13 Flue Hood
For access, refer to section 15.1.
Remove heat exchanger as described in section 15.12.
Remove the two securing screws and pull the flue hood down
and away from the flue hood bracket and flue elbow, see
diagram 15.9.
Diagram 15.8
13281
Diagram 15.9
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57
15 Replacement of Parts
For access, refer to section 15.1.
13316
15.14 Heating Flow Thermistor
Refer to diagram 15.10.
Remove the electrical connections from the thermistor.
Remove the retaining clip from the flow pipe.
NOTE: When reconnecting, the polarity of the wiring to
thermistors is not important.
15.15 Heating Return Thermistor
For access, refer to section 15.1.
Refer to diagram 15.10.
Remove the electrical connections from the thermistor.
Remove the retaining clip from the return pipe.
NOTE: When reconnecting, the polarity of the wiring to
thermistors is not important.
15.16 Condense Drain
For access, refer to section 15.1.
Refer to diagram 15.11.
Remove the igniter unit as described in section 15.3 to
improve accessibility.
Remove the securing clip from the heat exchanger adapter,
then disconnect the adapter and flexible hose.
Lift the siphon adapter and hose out of the condensate trap
and siphonic drain, do not disconnect the hose.
Disconnect the drain connection.
The condense trap will contain water, lift taking care not to
spill the water.
13544
Slacken to disengage but do not remove the two securing
screws.
Diagram 15.10
After replacement and before fitting the adapter fill the trap
with water.
Cleaning
Remove the condense trap as previously described.
Remove the float to clean it.
Remove any solids found.
Flush water through the trap to remove any remaining solids.
Check for any debris in the outlet hose of the condensate
drain and clean as necessary.
Diagram 15.11
58
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15 Replacement of Parts
For access, refer to section 15.1.
13257
15.17 Pump (head only)
Drain the boiler heating circuit as described in the appropriate
section of 15.1.
Refer to diagram 15.12.
Remove the four cap head screws.
Carefully remove the pump head together with cable. Do not
strain cable.
Support the pump head, unscrew cable cover at the side of
pump head and take off.
Disconnect wiring from pump head.
Reconnect wiring to new pump head and fit cover.
Fit the new pump head with ‘O’ ring.
Complete pump replacement
For access, refer to section 15.1.
Refer to diagram 15.12, 15.13.
13589
Drain the boiler heating circuit as described in the appropriate
section of 15.1.
Remove the pump head as described in section 15.17.
Remove the safety discharge valve as described in section
15.18.
Disconnect the expansion vessel pipe at the coupling, see
diagram 15.6 and at the pump housing by removing the
securing clip, see diagram 15.12.
Disconnect the central heating flow pipe union connection and
withdraw the pump securing clip.
Spring back the rear location bracket to release the pump
housing and gently rotate backwards and forwards whilst
easing the pump to the right to disengage from the 3 way
valve.
15.18 Safety Discharge Valve
For access, refer to section 15.1.
Drain the boiler heating circuit as described in the appropriate
section of 15.1.
Refer to diagram 15.13.
Remove the securing clip and withdraw the safety discharge
valve.
13256
Undo the safety discharge valve union and remove from the
pipework.
Diagram 15.12
Fit new ‘O’ ring.
Refill, vent and pressurise the boiler.
Diagram 15.13
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59
15 Replacement of Parts
13550
15.19 Domestic Hot Water Thermistor
For access, refer to section 15.1.
Refer to diagram 15.14.
Disconnect the domestic hot water thermistor electrical
connections
Remove hot water thermistor and retaining clip.
Remove domestic hot water thermistor from clip.
NOTE: When reconnecting electrical connections, polarity is
not important.
Carry out a functional test of the controls.
15.20 Automatic Air Vent
For access, refer to section 15.1.
Drain the boiler heating circuit as described in the appropriate
section of 15.1.
Refer to diagram 15.15 and gain access through the plastic
maintenance cover.
Diagram 15.14
Unscrew the automatic air vent.
Refill, vent and pressurise the boiler.
15.21 Low Water Pressure Sensor
MAINTENANCE
COVER
RETAINING
AUTOMATIC
CLIP
AIR VENT
13258
Fit the new automatic air vent and ‘O’ ring ensuring the vent
cap is left loose.
For access, refer to section 15.1.
Drain the boiler heating circuit as described in the appropriate
section of 15.1.
Refer to diagram 15.16.
Disconnect the electrical lead.
Remove the retaining clip, remove the low water pressure
sensor.
Fit new ‘O’ ring.
Fit the new low water pressure sensor.
Refill vent and pressurise the boiler.
Diagram 15.15
13315
Diagram 15.16
60
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15 Replacement of Parts
For access, refer to section 15.1.
Drain the boiler hot water circuit as described in the
appropriate section of 15.1.
13282
15.22 Flow Sensor
Refer to diagram 15.17.
Remove the front securing clip.
Disconnect the domestic cold water pipe at the bulkhead
connection and remove the pipe.
Remove the rear securing clip.
Disengage the flow sensor housing.
Remove the electrical connection.
Fit new ‘O’ rings.
After replacing the flow sensor, open the cold-water isolation
valve and slowly open a hot water tap to remove air.
15.23 Bypass
For access, refer to section 15.1.
Drain the boiler heating circuit as described in the appropriate
section of 15.1.
Refer to diagram 15.18.
Remove the retaining clip to remove the bypass screw.
Fit new ‘O’ rings.
After replacing the bypass, refill, vent and pressurise the
boiler.
15.24 Three Way Valve
Drain the boiler heating circuit as described in the appropriate
section of 15.1.
13259
For access, refer to section 15.1.
Diagram 15.17
Refer to diagram 15.18.
Remove the retaining clips and three securing screws to
remove the three way valve.
Undo the securing nut to check the solenoid actuator, spindle
and shaft.
Fit new ‘O’ rings before replacing the three way valve
assembly.
Refill, vent and pressurise the boiler.
15.25 Plate-to-Plate Heat Exchanger
For access, refer to section 15.1.
Drain the boiler heating and domestic hot water circuits as
described in the appropriate sections of 15.1.
Refer to diagram 15.19.
Remove the 4 securing screws.
Diagram 15.18
Remove the plate-to-plate heat exchanger by lifting it up and
over the top of the left hand hydroblock.
When replacing the plate-to-plate heat exchanger ensure that
the four rubber sealing washers are fitted into the hydroblock.
NOTE: The plate-to-plate heat exchanger only fits one way.
Refill, vent and pressurise the boiler.
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61
15 Replacement of Parts
13331
Disconnect the CH flow, return and DHW inlet pipes at the
bulkhead connectors, then the retaining clips, remove the
pipes and “o” ring seals.
Remove the low water pressure sensor as described in
section 15.21.
Remove the flow sensor as described in section 15.22.
Remove the 3 way valve as described in section 15.24.
Remove the pump as described in section 15.17.
Remove the plate to plate heat exchanger, refer to section
15.25.
Disconnect the central heating flow at the heat exchanger
connector then remove the retaining clip at the hydroblock.
Disconnect the pipe and “O” ring.
Remove clips from the plastic LH and RH hydroblocks
retaining the DHW, DCW and heating flow pipes, see diagram
15.20.
Remove the CH filter from the heating flow pipe port in the LH
hydroblock. The filter is a push-fit in the hydroblock port.
Grip the LH and RH hydroblocks simultaneously and lift clear
of the spigots on the mounting bracket.
Diagram 15.19
NOTE: Before removing the bypass tube from the
hydroblocks, take note of the tube position and orientation.
15.26 Hydroblock and Bypass Tube
For access, refer to section 15.1.
Fit the new bypass tube with new ‘O’ ring seals and reassemble to hydroblocks.
IMPORTANT: To replace the bypass tube and seals the LH
and RH hydroblocks will need to be removed. The following
procedure must also be used for the replacement of either the
LH or RH hydroblock.
Before refitting the plate to plate heat exchanger ensure that
the four rubber seals are in place, two in the LH and two in the
RH hydroblock.
Refer to section 15.1 and drain the boiler heating circuit and
the boiler domestic water circuit.
Fit new ‘O’ rings to pipes.
Refill system, vent and pressurise the boiler.
RETAINING
CLIP
MOUNTING
BRACKET
13588
RH HYDROBLOCK
DCW INLET
RETAINING CLIP
LH HYDROBLOCK
DHW OUTLET
RETAINING CLIP
PLATE TO PLATE
RUBBER SEAL
(4 OFF)
SPIGOT (4 OFF)
BYPASS
TUBE
3 WAY VALVE SEALS
CH FLOW
(from heat
exchanger)
DCW INLET
FILTER
(in Hydroblock)
DHW OUTLET
CH FLOW
Diagram 15.20
62
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15 Replacement of Parts
13535
15.27 Appliance Interface and Main PCB
For access, refer to section 15.1.
Remove control box retaining screw, see diagram 15.21.
Hinge down the control box.
Release the control box cover by carefully pressing the four
retaining latches, see diagram 15.21.
15.28 Main PCB
IMPORTANT: When replacing the board refer to instructions
supplied with the replacement.
For access, refer to section 15.27.
Remove the electrical connections to the PCB.
Ease back the four PCB retaining clips and withdraw the PCB
from the retaining lugs, see diagram 15.22.
When refitting the rear panel ensure the leads are not
trapped.
Diagram 15.21
When replacing the board refer to instructions supplied with
the replacement.
13313
15.29 Appliance Interface
IMPORTANT: When replacing the board refer to instructions
supplied with the replacement.
Refer to section 15.27 for access.
Remove main PCB, refer to section 15.28.
Remove electrical connection.
Gently ease back the retaining clips, see diagram 15.23.
Withdraw the board.
15.30 Fuse, Main PCB - Control Box
For access, refer to section 15.27.
The fuse is located at top left hand side of the PCB, see
diagram 15.22.
15.31 Control Box
For access, refer to section 15.27.
Remove relevant plugs and connectors, refer to wiring
diagram 14.4.
Diagram 15.22
Withdraw grommets and leads so they are hanging loose.
RETAINING
CLIPS
ELECTRICAL
CONNECTION
13671
Unthread the retaining cord and remove the control box by
drawing it outwards away from its retaining slots, see diagram
15.21.
15.32 Inner Casing Panel Seal
For access, refer to section 15.1.
Refer to diagram 13.8.
Remove the inner casing panel.
To replace remove the old seal, thoroughly clean the casing
surfaces. Fit the new seal, it is supplied to the correct length.
Refit the inner casing panel.
NOTE: Ensure the seal is fitted correctly giving an airtight
joint.
APPLIANCE INTERFACE
BOARD
Diagram 15.23
Supplied By www.heating spares.co Tel. 0161 620 6677
63
16 Spare Parts
16.1 Spare Parts
When ordering spare parts, contact Glow-worm’s own service organisation using the telephone number on the inside front cover of
this booklet. Please quote the name of the appliance and serial number, to be found on the data label. If ordering from British Gas
also quote the G.C. number of the part.
64
Key No.Part No.
12000802463
12000801840
2
0020014173
3
0020014161
4
0020014171
5
801655
6
0020038061
7
0020023825
8
0020037309
9
2000802664
10
0020014174
11
0020014169
12
0020014168
13
0020014160
14
0020020781
15
0020014402
16
2000802462
17
801635
Description
Burner - 24cx
Burner- 30cx
Pressure Relief Valve
Automatic Air Vent
Pump
Igniter
Appliance Interface
Main PCB
Fan
Gas Valve
Flow Sensor
Bypass
3 Way Valve
Domestic Hot Water Thermistor
NTC
Plate to Plate Heat Exchanger
Electrode
Burner Door Seal Kit
Supplied By www.heating spares.co Tel. 0161 620 6677
GC Part No.
E84021
E88867
H42758
H42754
H42760
E84015
H52596
H42783
H53083
E84004
H43155
H42768
H42766
H36325
720340
H43160
H53089
E85008
16 Spare Parts
13734
1
17
16
15
14
2
12
13
3
11
9
4
10
5
8
7
6
Diagram 16.1
Supplied By www.heating spares.co Tel. 0161 620 6677
65
17 Manual Handling
IMPORTANT. With regards to the Manual Handling Operations, 1992
Regulations, the following lift operation exceeds the recommended
weight for a one man lift.
General recommendations when handling
Clear the route before attempting the lift.
Ensure safe lifting techniques are used – keep back straight – bend
using legs. Keep load as close to body as possible. Do not twist –
reposition feet instead. If 2 persons performing lift, ensure co-ordinated movements during lift. Avoid upper body/top heavy bending - do
not lean forward/sideways. Recommend wear suitable cut resistant
gloves with good grip to protect against sharp edges and ensure good
grip.
Always use assistance if required.
Removal of carton from delivery van
Recommend 2 person lift or 1 person with use of sack truck. If 1
person is performing lift, straddle the load, tilt and place carton into
position on truck. Recommend secure appliance onto truck with
suitable straps. Ensure safe lifting techniques are used – keep back
straight – bend using legs. Keep load as close to body as possible. If
2 persons performing lift, ensure co-ordinated movements during lift.
Always use assistance if required.
Carriage of carton from point of delivery to point of installation –
ground floor.
Recommend 2 person lift or 1 person with use of sack truck. If 1 person is performing lift, straddle the load, tilt and place carton into position on truck. Recommend secure appliance onto truck with suitable
straps. Ensure safe lifting techniques are used – keep back straight –
bend using legs. Keep load as close to body as possible. If 2 persons
performing lift, ensure co-ordinated movements during lift. Clear the
route before attempting the lift. If removing boiler from truck straddle
the load and tilt forwards to facilitate secure grip. Ensure safe lifting
techniques are used – keep back straight – bend using legs. Do not
twist – reposition feet instead. Take care to avoid trip hazards, slippery or wet surfaces and when climbing steps and stairs. Always use
assistance if required.
Carriage of carton from point of delivery to point of installation –
first or higher floor, cellar.
Recommend 2-person lift or 1 person with use of sack truck. If 1
person is performing lift, straddle the load, tilt and place carton into
position on truck. Recommend secure appliance onto truck with
suitable straps. Ensure safe lifting techniques are used – keep back
straight – bend using legs. Keep load as close to body as possible. If
2 persons performing lift, ensure co-ordinated movements during lift.
Avoid upper body/top heavy bending - do not lean forward/sideways.
Clear the route before attempting the lift. If removing boiler from truck
straddle the load and tilt forwards to facilitate secure grip. Ensure safe
lifting techniques are used – keep back straight – bend using legs.
Do not twist – reposition feet instead. Take care to avoid trip hazards,
slippery or wet surfaces and when climbing steps and stairs. Always
use assistance if required.
Carriage of carton from point of delivery to point of installation –
roofspace.
Recommend 2-person lift. Ensure co-ordinated movements during lift.
Avoid upper body/top heavy bending - do not lean forward/sideways.
Clear the route before attempting the lift. Take care to avoid trip
hazards, slippery or wet surfaces and when climbing steps and stairs.
When transferring appliance into roofspace, recommend 1 person to
be in roofspace to receive the appliance and other person to be below
to pass up and support appliance. Ensure safe lifting techniques are
used – keep back straight – bend using legs. Keep load as close to
body as possible. Always use assistance if required. It is assumed
safe access, flooring and adequate lighting are provided in the roof
space. It is recommended a risk assessment of the roof space area
be carried out before moving the appliance into the area to take into
account access, stability of flooring, lighting and other factors, and
appropriate measures taken.
Positioning of Appliance for Final Installation – no obstructions.
Recommend 2 persons lift appliance to position into place. Fit bracket
securely onto wall before lifting appliance into position. Obtain firm
grip on front and sides of appliance, lift upwards, ensure stable balance achieved and lift upwards to position in place on bracket. Ensure
safe lifting techniques are used – keep back straight – bend using
legs - when lifting load from floor level. Do not twist – reposition feet
instead. Keep boiler as close as possible to body throughout lift to
minimise strain on back. Ensure co-ordinated movements to ensure
equal spread of weight of load. Always use assistance if required.
Recommend wear suitable cut resistant gloves with good grip to
protect against sharp edges and ensure good grip when handling
appliance.
Positioning of Appliance for Final Installation – above worktop,
foreseeable obstructions etc.
Recommend 2 persons lift appliance to position into place. Fit bracket
securely onto wall before lifting appliance into position. Obtain firm grip
on front and sides of appliance, lift upwards, onto worktop if practicable.
Ensure stable balance achieved and lift upwards to position in place on
bracket. If 2 persons positioning onto bracket obtain firm grip at front
and sides/base of boiler. Ensure co-ordinated movements during 2
person lifts to ensure equal spread of weight of load. Ensure safe lifting
techniques are used – keep back straight – bend using legs - when lifting load from floor level. Do not twist – reposition feet instead. Keep
boiler as close as possible to body throughout lift to minimise strain on
back. Avoid upper body/top heavy bending - do not lean forward/sideways. Always use assistance if required. Recommend wear suitable
cut resistant gloves with good grip to protect against sharp edges and
ensure good grip when handling appliance.
Positioning of Appliance for Final Installation – within compartment etc. restricting installation.
Recommend 2 persons lift appliance to position into place, space permitting. Fit bracket securely onto wall before lifting appliance into position. Obtain firm grip on front and sides of appliance, lift upwards,
onto worktop if practicable. Ensure stable balance achieved and lift
upwards to drop into place onto bracket. If 2 persons positioning onto
bracket obtain firm grip at front and sides/base of boiler. Ensure coordinated movements during 2 person lifts to ensure equal spread of
weight of load. If 1 person positioning onto bracket recommend obtain
firm grip supporting base of boiler. Ensure safe lifting techniques are
used – keep back straight – bend using legs - when lifting load from
floor level. Do not twist – reposition feet instead. Keep boiler as close
as possible to body throughout lift to minimise strain on back. Always
use assistance if required. Recommend wear suitable cut resistant
gloves with good grip to protect against sharp edges and ensure good
grip when handling appliance.
Positioning of Appliance for Final Installation – in roof space restricting installation.
Recommend 2 persons lift appliance to position into place, space permitting. Fit bracket securely onto wall before lifting appliance into position. Obtain firm grip on front and sides of appliance, lift upwards,
ensure stable balance achieved and lift upwards to drop into place onto
bracket. If 2 persons positioning onto bracket obtain firm grip at front
and sides/base of boiler. Ensure co-ordinated movements during 2
person lifts to ensure equal spread of weight of load. If 1 person positioning onto bracket recommend obtain firm grip supporting base of
boiler. Ensure safe lifting techniques are used - keep back straight –
bend using legs - when lifting load from floor level. Do not twist – reposition feet instead. Keep boiler as close as possible to body throughout
lift to minimise strain on back. Always use assistance if required. Recommend wear suitable cut resistant gloves with good grip to protect
against sharp edges and ensure good grip when handling appliance.
It is recommended a risk assessment of the roof space area be carried out before moving the appliance into the area to take into account
access, stability of flooring, lighting and other factors, and appropriate
measures taken.
Unpacking of appliance from carton.
Recommend 2 persons unpack appliance from carton. Always keep
working area clear. Cut the carton straps, lift carton up and slide over
polystyrene end packs. Remove top polystyrene pack with fittings.
66
Supplied By www.heating spares.co Tel. 0161 620 6677
Supplied By www.heating spares.co Tel. 0161 620 6677
67
0020040955-04 09.09
Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.
Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT
www.high-efficiency.info
Supplied By www.heating spares.co Tel. 0161 620 6677
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